Thermoplastic resin composition and resin molded product

ABSTRACT

The present invention relates to a thermoplastic resin composition comprising an aromatic polycarbonate resin (component A) [which may comprise an aromatic polycarbonate resin (component A1) and a thermoplastic resin other than the aromatic polycarbonate resin (component A2)], a granular talc (component B) having a bulk density of 0.4 to 1.5 g/mL which is obtained by granulating a talc having an average particle size of 0.1 to 10 μm, a rubber polymer (component C; optional component), a flame retardant (component E; optional component) and a fluorinated polyolefin (component F; optional component), wherein the granular talc (component B) has a particle size in which a proportion of a 500 μm-mesh screen residue thereof is not less than 55% by weight; as well as a resin molded product obtained by molding the thermoplastic resin composition. The thermoplastic resin composition and the resin molded product are excellent in extrusion moldability, rigidity, flame retardant, impact resistance and thermal stability, and exhibit an excellent balance between these properties.

This application is a divisional of application Ser. No. 12/281,733filed Sep. 4, 2008, which in turn is the U.S. national phase ofInternational Application No. PCT/JP2007/000145, filed 28 Feb. 2007,which designated the U.S. and claims priority to Japanese ApplicationNos. 2006-060303, filed 6 Mar. 2006, 2006-060304, filed 6 Mar. 2006 and2006-118980 filed 24 Apr. 2006, the entire contents of each of which arehereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a thermoplastic resin composition and aresin molded product, and more particularly, to a thermoplastic resincomposition obtained by incorporating a specific granular talc into aresin component comprising an aromatic polycarbonate resin which isenhanced in thermal stability, impact resistance, rigidity, extrusionmoldability and flame retardancy, and exhibits an excellent balancebetween these properties, and a resin molded product obtained from thethermoplastic resin composition.

BACKGROUND ART

Aromatic polycarbonate resins have been used as general-purposeengineering plastics in various extensive applications such as parts ofelectric, electronic and OA equipments, mechanical parts and vehicleparts because the resins are excellent in various properties such astransparency, impact resistance, heat resistance and dimensionalstability. In addition, polymer alloys comprising an aromaticpolycarbonate resin and a thermoplastic polyester resin are known asmaterials that are improved in chemical resistance and moldability aspoor properties of the aromatic polycarbonate resins while maintainingthe above excellent properties inherent to the aromatic polycarbonateresins, and have been used in the applications such as interior andexterior parts and outside plate parts for vehicles and various housingmembers, as well as in the other extensive applications.

In order to improve a rigidity and a dimensional stability of thepolymer alloys comprising an aromatic polycarbonate resin and athermoplastic resin other than the aromatic polycarbonate resin such asa thermoplastic polyester resin, in general, there is widely known amethod of incorporating an inorganic filler such as glass fiber and talcinto the polymer alloys. However, when the glass fiber is blended in thepolymer alloys, a molded product obtained from such polymer alloys tendsto be deteriorated in appearance on the surface thereof, resulting inonly limited applications to exterior parts and outside plate parts forvehicles requiring a good appearance.

On the other hand, although the resin composition containing a talcprovides a molded product having a good appearance, decomposition of thearomatic polycarbonate resin as well as transesterification reactionbetween the aromatic polycarbonate resin and the thermoplastic polyesterresin tend to excessively proceed owing to a strong basicity of thetalc, resulting in poor thermal stability of the resin composition.

In particular, there is such a recent tendency that exterior parts andoutside plate parts for vehicles are required to have a large size and ahigh rigidity as a molded product. Therefore, it has been demanded toprovide such a material capable of exhibiting excellent thermalstability and impact resistance. Also, as to the impact resistancerequired for these molded products, an elongation at break or a surfaceimpact strength becomes more important than Izod impact strength owingto the relation with strain rate. As a result, it is required to providea material capable of improving these impact properties by blending atalc in the resin composition.

To solve the problem concerning poor thermal stability of the resincomposition when blending a talc therein, there have been proposed aresin composition containing a specific rubber polymer (for example,refer to Patent Document 1), a resin composition containing a specificphosphorus-based stabilizer (for example, refer to Patent Documents 2and 3), and a resin composition using a surface-treated talc (forexample, refer to Patent Document 4). However, in these conventionaltechniques, the obtained resin compositions tend to be unsatisfactory inthermal stability and impact resistance. Therefore, it has been stronglyrequired to improve these properties of the resin compositions.

On the other hand, there have been proposed a resin composition using atalc that is increased in bulk specific gravity by mechanicalcompression (for example, refer to Patent Documents 5 and 6), and aresin composition using a talc having a limited electric conductivity(for example, refer to Patent Document 7). In the Patent Document 7, itis described that the talc is preferably in the form of a compressed andgranulated product, and the talc may be granulated using a binder.

However, in the conventional techniques specifically illustrated inthese Patent Documents, the obtained resin compositions are stillunsatisfactory in thermal stability and impact resistance. Further, inPatent Document 8, there has been proposed the technique concerning sucha talc that is formed into granules using a binder, and it is describedthat polycarbonate resins, polyester resins, rubber-based resins as wellas plural kinds of these resins may be used as the binder. However, thetechnique described in the Patent Document 8 neither teaches norsuggests the above problems caused upon blending the talc in thearomatic polycarbonate resins. Therefore, it is not possible to obtain aresin composition having satisfactory thermal stability and impactresistance only by blending the granular talc in the aromaticpolycarbonate resins.

In addition, although the aromatic polycarbonate resins have been usedin extensive applications, among them, in the applications such as partsof electric, electronic and OA equipments, these products have beenstrongly required to exhibit especially a good flame retardancy. Forthis reason, there is extensively known such a general technique ofblending various flame retardants in the aromatic polycarbonate resinsto impart a good flame retardancy thereto.

As the resin composition containing a flame retardant, such resincompositions containing a halogen-based flame retardant such as brominecompounds have been used for a long time. These resin compositionsexhibit a high flame retardancy, but suffer from the problem concerninghigh burden on environments. Therefore, there have been proposed anumber of resin compositions containing a non-halogen-based flameretardant.

Further, the aromatic polycarbonate resins tend to be deteriorated influidity. Therefore, resin compositions obtained by incorporating anorganic phosphate-based flame retardant into a polymer alloy comprisingan aromatic polycarbonate resin and a styrene-based resin such asacrylonitrile-butadiene-styrene copolymer (ABS resin) have beenextensively used especially in the applications of housings for OAequipments such as personal computers and printers.

In recent years, in the applications of parts of electric, electronicand OA equipments, the thickness thereof has been rapidly reduced, sothat it has been demanded to provide a material capable of exhibiting agood appearance and a high rigidity. For instance, there has beenproposed a flame-retardant resin composition containing an inorganicfiller having a small particle size such as talc (for example, refer toPatent Document 9). However, the resin compositions obtained by blendingthe talc in aromatic polycarbonate resins tend to suffer from problemssuch as decomposition of the aromatic polycarbonate resins and,therefore, poor thermal stability and impact resistance owing to astrong basicity of the talc, notwithstanding such an advantage that themolded product obtained therefrom can exhibit a good appearance.Further, the resin compositions containing the non-halogen-based flameretardant also tend to suffer from such a problem that the flameretardancy of these compositions is deteriorated as the content of thetalc therein increases.

To solve the above problems, there has been proposed a flame-retardantresin composition containing a surface-treated inorganic filer (forexample, refer to Patent Documents 10 to 12). However, in theconventional techniques described in these Patent Documents, theobtained resin compositions are still unsatisfactory in flame retardancyand thermal stability. Further, when blending a talc having a smallparticle size in the resin compositions, there tend to arise problemssuch as clogging of a hopper, deteriorated extrusion moldability such aspoor intrusion into an extruder, and poor impact resistance of theresultant resin composition owing to poor dispersion of the talctherein.

As described above, in the application fields of the thermoplastic resincompositions comprising an aromatic polycarbonate resin into which atalc having a small particle size and a non-halogen-based flameretardant are blended, it has been strongly demanded to develop thetechniques for enhancing an extrusion moldability, a rigidity, a flameretardancy, an impact resistance and a thermal stability thereof.

To solve the above conventional problems, there have been proposed aresin composition using a talc that is increased in bulk specificgravity by mechanical compression (for example, refer to Patent Document5), and a resin composition using a talc having a limited electricconductivity (for example, refer to Patent Document 7). In particular,in the Patent Document 7, it is described that the talc is preferably inthe form of a compressed and granulated product, and the talc may begranulated using a binder. However, in these Patent documents, nospecific examples concerning such features of the resin compositions aredescribed, and further the obtained resin compositions are stillunsatisfactory in extrusion moldability, flame retardancy, impactresistance and thermal stability.

On the other hand, there have been proposed the technique concerning aninorganic filler that is formed into a granular shape using a binder(for example, refer to Patent Document 8), and a thermoplastic resincomposition obtained by blending a granular talc granulated using aspecific amount of bentonite, in an aromatic polycarbonate resin (forexample, refer to Patent Document 13). However, in these PatentDocuments, it is merely described that the flame retardant may beblended in the composition, but there is no description concerning aresin composition comprising an aromatic polycarbonate resin, and agranular talc and a non-halogen-based flame retardant blended in theresin which is excellent in flame retardancy and thermal stability.

Patent Document 1: Japanese Patent Application Laid-Open (KOKAI) No.2001-294741

Patent Document 2: Japanese Patent Application Laid-Open (KOKAI) No.5-222283 (1993)

Patent Document 3: Japanese Patent Application Laid-Open (KOKAI) No.6-49343 (1994)

Patent Document 4: Japanese Patent Application Laid-Open (KOKAI) No.8-127711 (1996)

Patent Document 5: Japanese Patent Application Laid-Open (KOKAI) No.8-176339 (1996)

Patent Document 6: Japanese Patent Application Laid-Open (KOKAI) No.10-101914 (1998)

Patent Document 7: Japanese Patent Application Laid-Open (KOKAI) No.2002-60637

Patent Document 8: Japanese Patent Application Laid-Open (KOKAI) No.2002-220549

Patent Document 9: Japanese Patent Application Laid-Open (KOKAI) No.2003-134304

Patent Document 10: Japanese Patent Application Laid-Open (KOKAI) No.10-338805 (1998)

Patent Document 11: Japanese Patent Application Laid-Open (KOKAI) No.2005-48072

Patent Document 12: Japanese Patent Application Laid-Open (KOKAI) No.2005-220216

Patent Document 13: Japanese Patent Application Laid-Open (KOKAI) No.2006-77176

DISCLOSURE OF THE INVENTION Problem to be Solved by the Invention

An object, of the present invention is to overcome the above problemsencountered in the prior art, and provide a thermoplastic resincomposition capable of exhibiting excellent extrusion moldability,rigidity, flame retardancy, impact resistance and thermal stability, andan excellent balance between these properties, as well as a resin moldedproduct obtained from the thermoplastic resin composition.

Means for Solving the Problem

As a result of the present inventors' earnest study for solving theabove conventional problems, it has been found that (1) thethermoplastic resin composition prepared by blending a granular talchaving specific bulk density and particle size in a specific resincomposition mainly comprising an aromatic polycarbonate resin and athermoplastic resin other than the aromatic polycarbonate resin can beenhanced in all of thermal stability, impact resistance and rigidity,and exhibit an excellent balance between these properties; (2) thethermoplastic resin composition prepared by blending a specific amountof a rubber polymer in a resin composition mainly comprising an aromaticpolycarbonate resin and a granular talc having specific bulk density andparticle size can exhibit excellent thermal stability, impact resistanceand rigidity; and (3) the thermoplastic resin composition prepared byblending a specific granular talc and a specific flame retardant in aresin component comprising an aromatic polycarbonate resin can beenhanced in all of extrusion moldability, rigidity, flame retardancy,impact resistance and thermal stability, and exhibit an excellentbalance between these properties. The present invention has beenattained on the basis of the above finding.

That is, in a first aspect of the present invention, there is provided athermoplastic resin composition comprising:

40 to 99 parts by weight of a resin component (component A) comprising10 to 90% by weight of an aromatic polycarbonate resin (component A1)and 90 to 10% by weight of a thermoplastic resin other than the aromaticpolycarbonate resin (component A2) with the proviso that a total contentof the components A1 and A2 is 100% by weight;

1 to 60 parts by weight of a granular talc (component B) having a bulkdensity of 0.4 to 1.5 g/mL which is obtained by granulating a talchaving an average particle size of 0.1 to 10 μm; and

0 to 35 parts by weight of a rubber polymer (component C),

wherein the granular talc (component B) has a particle size in which aproportion of a 500 μm-mesh screen residue thereof is not less than 55%by weight.

In a second aspect of the present invention, there is provided a resinmolded product produced by molding the thermoplastic resin compositionas defined in the above first aspect.

In a third aspect of the present invention, there is provided athermoplastic resin composition comprising:

40 to 99 parts by weight of an aromatic polycarbonate resin (componentA);

1 to 60 parts by weight of a granular talc (component B) having a bulkdensity of 0.4 to 1.5 g/mL which is obtained by granulating a talchaving an average particle size of 0.1 to 10 μm; and

a rubber polymer (component C) in an amount of 3 to 35 parts by weighton the basis of 100 parts by weight of a total amount of the componentsA and B,

wherein the granular talc (component B) has a particle size in which aproportion of a 500 μm-mesh screen residue thereof is not less than 55%by weight.

In a fourth aspect of the present invention, there is provided a resinmolded product produced by molding the thermoplastic resin compositionas defined in the above third aspect.

In a fifth aspect of the present invention, there is provided athermoplastic resin composition comprising:

40 to 99 parts by weight of a resin component (component A) comprising50 to 100% by weight of an aromatic polycarbonate resin (component A1)and 50 to 0% by weight of a thermoplastic resin other than the aromaticpolycarbonate resin (component A2) with the proviso that a total contentof the components A1 and A2 is 100% by weight;

1 to 60 parts by weight of a granular talc (component B) having a bulkdensity of 0.4 to 1.5 g/mL which is obtained by granulating a talchaving an average particle size of 0.1 to 10 μm; and

at least one flame retardant (component E) selected from the groupconsisting of an organic alkali metal salt and/or an organic alkaliearth metal salt (component E1), an organophosphorus-based flameretardant (component E2) and a silicone-based resin (component E3); anda fluorinated polyolefin (component F), said components E and F beingpresent in amounts of 0.01 to 40 parts by weight and 0.01 to 5 parts byweight, respectively, on the basis of 100 parts by weight of a totalamount of the components A and B,

wherein the granular talc (component B) has a particle size in which aproportion of a 500 μm-mesh screen residue thereof is not less than 55%by weight.

In a sixth aspect of the present invention, there is provided a resinmolded product produced by molding the thermoplastic resin compositionas defined in the above fifth aspect.

EFFECT OF THE INVENTION

The thermoplastic resin composition as described in the first aspect ofthe present invention has such an advantage that the resin compositionis excellent in all of thermal stability, impact resistance andrigidity, and exhibits an excellent balance between these properties.The thermoplastic resin composition according to the first aspect of thepresent invention which has the above advantage can be used in variousextensive applications. Specific examples of the applications of thethermoplastic resin composition according to the first aspect of thepresent invention include parts of electric and electronic equipments,parts of OA equipments, mechanical parts, vehicle parts, buildingmembers, various containers, leisure goods, sundries, various housingsfor cellular phones, etc. In addition, the thermoplastic resincomposition according to the first aspect of the present invention canalso be suitably used especially as exterior parts, outside plate partsand interior parts for vehicles because the resin composition isexcellent in not only a balance between thermal stability, impactresistance and rigidity, but also chemical resistance and appearance.

The thermoplastic resin composition as described in the third aspect ofthe present invention has such an advantage that the resin compositionis excellent in thermal stability, impact resistance and rigidity. Thethermoplastic resin composition according to the third aspect of thepresent invention which has the above advantage can be used in variousextensive applications. Specifically, the thermoplastic resincomposition according to the third aspect of the present invention canbe usefully used in the applications such as electric and electronicequipments or parts thereof, OA equipments, information terminalequipments, mechanical parts, domestic appliances, vehicle parts,building members, various containers, leisure goods, sundries, variousillumination equipments, etc. In particular, it is expected that thethermoplastic resin composition according to the third aspect of thepresent invention can also be applied to housing members for electricand electronic equipments, OA equipments and information terminalequipments, and exterior parts, outside plate parts and interior partsfor vehicles.

The thermoplastic resin composition as described in the fifth aspect ofthe present invention has such an advantage that the resin compositionis enhanced in all of extrusion moldability, rigidity, flame retardant,impact resistance and thermal stability, and exhibits an excellentbalance between these properties. The thermoplastic resin compositionaccording to the third aspect of the present invention which has theabove advantage can be used in various extensive applications.Specifically, the thermoplastic resin composition according to the fifthaspect of the present invention can be usefully used in the applicationssuch as parts of electric and electronic equipments, OA equipments,mechanical parts, vehicle parts, building members, various containers,leisure goods, sundries, and parts of information terminal equipmentssuch as cellular phones. In particular, the thermoplastic resincomposition according to the fifth aspect of the present invention aresuitably used especially as parts of electric and electronic equipments,parts of OA equipments and parts of information terminal equipments.

Specific examples of the housing members and parts of electric andelectronic equipments, OA equipments and information terminal equipmentsinclude displays of personal computers, game equipments, televisions,etc., and housing members or inside parts of printers, copying machines,scanners, facsimiles, electronic pocket books or PDA, battery packs,cameras, video cameras, cellular phones, driving devices or readers forrecording media, etc.

Specific examples of the exterior parts and outside plate parts forvehicles include outer door handles, bumpers, fenders, door panels,trunk lids, front panels, rear panels, roof panels, bonnets, pillars,side moldings, garnishes, wheel caps, hood bulges, fuel lids, variousspoilers, and cowlings of motorcycles. Specific examples of the interiorparts for vehicles include inner door handles, center panels, instrumentpanels, console boxes, luggage floor boards, and housings of displaysfor car navigation, etc.

PREFERRED EMBODIMENTS FOR CARRYING OUT THE INVENTION

The present invention is described in detail below. However, thefollowing detailed descriptions are concerned with only typical examplesof preferred embodiments of the present invention, and not intended tolimit the scope of the present invention thereto. In the followingdescriptions, the thermoplastic resin composition is occasionallyreferred to merely as a “resin composition”. Meanwhile, in the presentspecification, the “group” contained in various compounds involves bothsubstituted and unsubstituted groups, unless departing from the scope ofthe present invention.

First, the thermoplastic resin composition according to the first aspectof the present invention is described. The thermoplastic resincomposition according to the first aspect of the present inventioncomprises 40 to 99 parts by weight of a resin component (component A)comprising 10 to 90% by weight of an aromatic polycarbonate resin(component A1) and 90 to 10% by weight of a thermoplastic resin otherthan the aromatic polycarbonate resin (component A2) with the provisothat a total content of the components A1 and A2 is 100% by weight; 1 to60 parts by weight of a granular talc (component B) having a bulkdensity of 0.4 to 1.5 g/mL which is obtained by granulating a talchaving an average particle size of 0.1 to 10 μm; and 0 to 35 parts byweight of a rubber polymer (component C), wherein the granular talc(component B) has a particle size in which a proportion of a 500 μm-meshscreen residue thereof is not less than 55% by weight.

Aromatic Polycarbonate Resin (Component A1):

The aromatic polycarbonate resin as the component A1 of thethermoplastic resin composition according to the first aspect of thepresent invention (hereinafter referred to merely as the “component A1”)is a linear or branched thermoplastic aromatic polycarbonate in the formof a polymer or copolymer which is obtained, for example, by reacting anaromatic dihydroxy compound and a carbonate precursor, or by reactingthese compounds with a small amount of a polyhydroxy compound, etc.

The aromatic polycarbonate resin (component A1) used in the presentinvention is not particularly limited, and may be produced by suitableknown method such as, for example, an interfacial polymerization method,a melting transesterification method, a pyridine method, a ring-openingpolymerization method of cyclic carbonate compounds, and a solid-statetransesterification method of prepolymers.

Examples of the aromatic dihydroxy compound used as a raw material ofthe aromatic polycarbonate resin include bis(hydroxyaryl)alkanes such as2,2-bis(4-hydroxyphenyl)propane (=bisphenol A),2,2-bis(3,5-bibromo-4-hydroxyphenyl)propane (=tetrabromobisphenol A),bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane,2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane,2,2-bis(4-hydroxy-3-methylphenyl)propane,1,1-bis(3-tert-butyl-4-hydroxyphenyl)propane,2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane,2,2-bis(3-bromo-4-hydroxyphenyl)propane,2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane,2,2-bis(3-phenyl-4-hydroxyphenyl)propane,2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane,1,1-bis(4-hydroxyphenyl)-1-phenylethane,bis(4-hydroxyphenyl)diphenylmethane,2,2-bis(4-hydroxyphenyl)-1,1,1-trichloropropane,2,2-bis(4-hydroxyphenyl)-1,1,1,3,3,3-hexachloropropane and2,2-bis(4-hydroxyphenyl)-1,1,1,3,3,3-hexafluoropropane;bis(hydroxyaryl)cycloalkanes such as1,1-bis(4-hydroxyphenyl)cyclopentane,1,1-bis(4-hydroxyphenyl)cyclohexane and1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane; bisphenols having acardo structure such as 9,9-bis(4-hydroxyphenyl)fluorene and9,9-bis(4-hydroxy-3-methylphenyl)fluorene; dihydroxydiaryl ethers suchas 4,4′-dihydroxydiphenyl ether and 4,4′-dihydroxy-3,3′-dimethyldiphenylether; dihydroxydiaryl sulfides such as 4,4′-dihydroxydiphenyl sulfideand 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfide; dihydroxydiarylsulfoxides such as 4,4′-dihydroxydiphenyl sulfoxide and4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfoxide; dihydroxydiaryl sulfonessuch as 4,4′-dihydroxydiphenyl sulfone and4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfone; hydroquinone; resorcin;and 4,4′-dihydroxydiphenyl.

Among the above aromatic dihydroxy compounds, preferred arebis(4-hydroxyphenyl)alkanes, and more preferred is2,2-bis(4-hydroxyphenyl)propane [=bisphenol A] from the viewpoint of agood impact resistance of the resultant resin composition. Thesearomatic dihydroxy compounds may be used alone or in combination of anytwo or more thereof.

Examples of the above carbonate precursor to be reacted with thearomatic dihydroxy compound include carbonyl halides, carbonic acidesters and haloformates. Specific examples of the carbonate precursorinclude phosgene; diaryl carbonates such as diphenyl carbonate andditolyl carbonate; dialkyl carbonates such as dimethyl carbonate anddiethyl carbonate; and dihaloformates of dihydric phenols. Thesecarbonate precursors may be used alone or in combination of any two ormore thereof.

Also, the aromatic polycarbonate resin (component A1) may be in the formof a branched aromatic polycarbonate resin obtained by copolymerizing atri- or more polyfunctional aromatic compound therewith. Examples of thetri- or more polyfunctional aromatic compound include polyhydroxycompounds such as fluoroglucin,4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-2,4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptane,2,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-3,1,3,5-tri(4-hydroxyphenyl)benzeneand 1,1,1-tri(4-hydroxyphenyl)ethane; 3,3-bis(4-hydroxyaryl)oxyindole(=isatin bisphenol); 5-chloroisatin; 5,7-dichloroisatin; and5-bromoisatin. Among these polyfunctional aromatic compounds, preferredis 1,1,1-tri(4-hydroxyphenyl)ethane. The polyfunctional aromaticcompound may be used by replacing a part of the above aromatic dihydroxycompound therewith. The amount of the polyhydroxy aromatic compound usedis preferably 0.01 to 10 mol % and more preferably 0.1 to 2 mol % on thebasis of the aromatic dihydroxy compound.

Next, the processes for producing the component A1 used in the presentinvention are described. Among these production processes of thecomponent A1, the production process using an interfacial polymerizationmethod is first explained. In the polymerization reaction of theproduction process, the aromatic dihydroxy compound is first reactedwith phosgene in the presence of an organic solvent inert to thereaction and an alkali aqueous solution while maintaining the reactionsystem at a pH of usually not less than 9, if required, using amolecular weight controller (end stopping agent) and an antioxidant forpreventing oxidation of the aromatic dihydroxy compound, and then apolymerization catalyst such as a tertiary amine or a quaternaryammonium salt is added to the reaction system to conduct an interfacialpolymerization therebetween, thereby obtaining a polycarbonate. The timeof addition of the molecular weight controller is not particularlylimited, and the molecular weight controller may be added at any timebetween the reaction with phosgene and initiation of the polymerizationreaction without particular limitations. Meanwhile, the reactiontemperature is, for example, 0 to 40° C., and the reaction time is, forexample, from several minutes (for example, 10 min) to several hours(for example, 6 hr).

Examples of the organic solvent inert to the reaction includechlorinated hydrocarbons such as dichloromethane, 1,2-dichloroethane,chloroform, monochlorobenzene and dichlorobenzene; and aromatichydrocarbons such as benzene, toluene and xylene. Examples of the alkalicompound used for preparing the aqueous alkali solution includehydroxides of alkali metals such as sodium hydroxide and potassiumhydroxide.

Examples of the molecular weight controller include compounds containinga monovalent phenolic hydroxyl group. Specific examples of the compoundscontaining a monovalent phenolic hydroxyl group include m-methyl phenol,p-methyl phenol, m-propyl phenol, p-propyl phenol, p-tert-butyl phenoland p-long chain alkyl-substituted phenols. The amount of the molecularweight controller used is preferably 50 to 0.5 mol and more preferably30 to 1 mol on the basis of 100 mol of the aromatic dihydroxy compound.

Examples of the polymerization catalyst include tertiary amines such astrimethylamine, triethylamine, tributylamine, tripropylamine,trihexylamine and pyridine; and quaternary ammonium salts such astrimethylbenzyl ammonium chloride, tetramethyl ammonium chloride andtriethylbenzeyl ammonium chloride.

Next, the production process using a melting transesterification methodis explained. The polymerization reaction of the production process maybe conducted, for example, by subjecting a carbonic diester and anaromatic dihydroxy compound to transesterification reaction. Examples ofthe carbonic diester include dialkyl carbonate compounds such asdimethyl carbonate, diethyl carbonate and di-tert-butyl carbonate;diphenyl carbonate; and substituted diphenyl carbonates such as ditolylcarbonate. Among these carbonic diesters, preferred are diphenylcarbonate and substituted diphenyl carbonates, and more preferred isdiphenyl carbonate.

Also, the amount of an end hydroxyl group contained in the aromaticpolycarbonate resin has a large influence on thermal stability,hydrolysis stability and color tone of the obtained polycarbonateproducts, and, therefore, may be appropriately controlled byconventionally known optional methods. In the case of the meltingtransesterification process, the mixing ratio between the carbonicdiester and the aromatic dihydroxy compound as well as the vacuum degreeused upon the transesterification reaction are usually controlled tothereby obtain an aromatic polycarbonate having a desired molecularweight in which the amount of the end hydroxyl group is desirablyadjusted.

In the melting transesterification reaction, the carbonate diester isusually used in not less than an equimolar amount and preferably in anamount of 1.01 to 1.30 mol on the basis of 1 mol of the aromaticdihydroxy compound. In order to positively control the amount of the endhydroxyl group, there may be used such a method of separately adding anend stopping agent upon the reaction. Examples of the end stopping agentinclude monohydric phenols, monovalent carboxylic acids and carbonicdiesters.

Upon producing the polycarbonates by the melting transesterificationmethod, the reaction is usually conducted in the presence of atransesterification catalyst. The transesterification catalyst used inthe reaction is not particularly limited, and is preferably an alkalimetal compound and/or an alkali earth metal compound. Thetransesterification catalyst may be used in combination with a basiccompound as an auxiliary component such as a basic boron compound, abasic phosphorus compound, a basic ammonium compound and an amine-basedcompound. The transesterification reaction using the above raw materialsmay be conducted at a temperature of 100 to 320° C., and then thetransesterification reaction product may be subjected tomelt-polycondensation reaction under reduced pressure finally reachingnot more than 2 mm Hg, while removing by-products such as aromatichydroxy compounds from the reaction mixture.

The melt-polycondensation may be conducted by either a batch method or acontinuous method, and is preferably conducted by a continuous methodfrom the viewpoints of a good stability, etc., of the aromaticpolycarbonate resin used in the present invention and the resultantresin composition of the present invention. Examples of the preferredcatalyst deactivator used in the melting transesterification methodinclude compounds capable of neutralizing the transesterificationcatalyst, for example, sulfur-containing acid compounds and derivativesformed therefrom. Such a compound capable of neutralizing thetransesterification catalyst is added in an amount of preferably 0.5 to10 equivalents and more preferably 1 to 5 equivalents on the basis ofthe alkali metal contained in the catalyst, and further preferably 1 to100 ppm and more preferably 1 to 20 ppm on the basis of thepolycarbonate.

The molecular weight of the aromatic polycarbonate resin (component A1)used in the present invention may be optionally determined, and iscontrolled such that the viscosity-average molecular weight [Mv]calculated from a solution viscosity thereof is preferably in the rangeof 10,000 to 50,000. The aromatic polycarbonate having aviscosity-average molecular weight of not less than 10,000 tends to befurther improved in mechanical strength, and can be therefore moresuitably used in the applications requiring a higher mechanicalstrength. Whereas, the aromatic polycarbonate having a viscosity-averagemolecular weight of not more than 50,000 tends to be more effectivelyprevented from undergoing deterioration in fluidity, and is morepreferable from the viewpoint of facilitated molding process.

The viscosity-average molecular weight of the aromatic polycarbonateresin (component A1) is more preferably 12,000 to 40,000 and still morepreferably 14,000 to 30,000. Also, two or more kinds of aromaticpolycarbonate resins that are different in viscosity-average molecularweight from each other may be used in the form of a mixture thereof.Further, the above aromatic polycarbonate resin may also be mixed withthose aromatic polycarbonate resins having a viscosity-average molecularweight which is out of the above-specified range, if required.

The viscosity-average molecular weight [Mv] used herein means the valuecalculated from an intrinsic viscosity [Ti] (unit: dL/g) as measured at20° C. in methylene chloride as a solvent using an Ubbellohdeviscometer, according to Schnell's viscosity formula:η=1.23×10⁻⁴M^(0.83) wherein the intrinsic viscosity [η] is the valuecalculated from a specific viscosity [η_(sp)] as measured at eachsolution concentration [C] (g/dL) according to the following formula:

$\eta = {\lim\limits_{c->0}{\eta_{sp}/{C.}}}$

The end hydroxyl group concentration of the aromatic polycarbonate resinused in the present invention is usually not more than 1000 ppm,preferably not more than 800 ppm and more preferably not more than 600ppm. The lower limit of the end hydroxyl group concentration of thearomatic polycarbonate resin, in particular, such an aromaticpolycarbonate resin produced by transesterification method, is not lessthan 10 ppm, preferably not less than 30 ppm and more preferably notless than 40 ppm.

When the end hydroxyl group concentration of the aromatic polycarbonateresin is controlled to not less than 10 ppm, the aromatic polycarbonateresin is prevented from undergoing reduction in a molecular weightthereof, resulting in such a tendency that the obtained resincomposition is further enhanced in mechanical properties. Also, when theend hydroxyl group concentration of the aromatic polycarbonate resin iscontrolled to not more than 1000 ppm, the obtained resin compositiontends to be further enhanced in retention thermal stability and colortone. Meanwhile, the unit of the above end hydroxyl group concentrationexpressed by “ppm” represents a weight of the end hydroxyl group basedon the weight of the aromatic polycarbonate resin. The end hydroxylgroup concentration may be measured by colorimetric quantitydetermination using a titanium tetrachloride/acetic acid method (themethod described in “Macromol. Chem.”, 88, 215 (1965)).

In addition, the aromatic polycarbonate resin (component A1) used in thepresent invention may also contain an aromatic polycarbonate oligomer inorder to improve an appearance of a molded product obtained therefrom aswell as a fluidity of the resin composition. The viscosity-averagemolecular weight [Mv] of the aromatic polycarbonate oligomer ispreferably 1,500 to 9,500 and more preferably 2,000 to 9,000. Thearomatic polycarbonate oligomer is usually used in an amount of not morethan 30% by weight based on the weight of the component A1.

Further, in the present invention, as the aromatic polycarbonate resin(component A1), there may also be used not only the virgin resin, butalso those aromatic polycarbonate resins regenerated from used resinproducts, i.e., so-called material-recycled aromatic polycarbonateresins. Examples of the used resin products include optical recordingmedia such as optical discs, light guide plates, transparent members forvehicles such as automobile window glass, automobile headlamp lenses andwindshields, containers such as water bottles, spectacle lenses, andbuilding materials such as sound insulating walls, glass windows andcorrugated sheets. Further, there may also be used nonconformingproducts and crushed or pulverized products obtained from sprues andrunners as well as pellets obtained by melting these products. Theamount of the regenerated aromatic polycarbonate resin used ispreferably not more than 80% by weight and more preferably not more than50% by weight based on the weight of the component A1.

Thermoplastic Resin Other than Aromatic Polycarbonate Resin (ComponentA2):

As the thermoplastic resin other than aromatic polycarbonate resin whichis used as the component A2 in the present invention (hereinafteroccasionally referred to merely as the “component A2”), there may beused various known optional thermoplastic resins. Specific examples ofthe thermoplastic resin include thermoplastic polyester resins such aspolyethylene terephthalate resin, polytrimethylene terephthalate resinand polybutylene terephthalate resin; styrene-based resins such aspolystyrene resin, high-impact polystyrene resin (HIPS),acrylonitrile-styrene copolymer (AS resin),acrylonitrile-butadiene-styrene copolymer (ABS resin),acrylonitrile-styrene-acrylic rubber resin (ASA resin) andacrylonitrile-ethylene/propylene-based rubber-styrene copolymer (AESresin); polyolefin resins such as polyethylene resin and polypropyleneresin; polyamide resins; polyimide resins; polyether imide resins;polyurethane resins; polyphenylene ether resins; polyphenylene sulfideresins; polysulfone resins; and polymethacrylate resins. Thesethermoplastic resins may be used alone or in combination of any two ormore thereof. Among these thermoplastic resins, the thermoplasticpolyester resins are especially preferred from the viewpoints of a goodthermal stability and a good rigidity.

The thermoplastic polyester resins which are especially preferably usedas the component A2 in the present invention are in the form of apolymer or copolymer obtained by subjecting a dicarboxylic acidcomponent comprising a dicarboxylic acid or a reactive derivativethereof, and a diol component comprising a diol or an ester derivativethereof, to condensation reaction.

The thermoplastic polyester resins (component A2) used in the presentinvention may be produced by any optional method. In general, thethermoplastic polyester resins may be produced by reacting thedicarboxylic acid component and the diol component under heating in thepresence of a polycondensation catalyst containing titanium, germanium,antimony, etc., while discharging water and lower alcohols asby-products from the reaction system. The condensation reaction may beconducted by either a batch polymerization method or a continuouspolymerization method. Further, the resultant polymer or copolymer maybe subjected to solid-state polymerization to increase a polymerizationdegree thereof.

The dicarboxylic acid may be either an aromatic dicarboxylic acid or analiphatic dicarboxylic acid. Among them, the aromatic dicarboxylic acidis preferred from the viewpoints of a good heat resistance and a gooddimensional stability. Specific examples of the aromatic dicarboxylicacid include terephthalic acid, isophthalic acid, orthophthalic acid,1,5-naphthalene dicarboxylic acid, 2,6-naphthalene dicarboxylic acid,4,4′-biphenyl dicarboxylic acid, 4,4′-biphenylether dicarboxylic acid,4,4′-biphenylmethane dicarboxylic acid, 4,4′-biphenylsulfonedicarboxylic acid, 4,4′-biphenylisopropylidene dicarboxylic acid,1,2-bis(phenoxy)ethane-4,4′-dicarboxylic acid, 2,5-anthracenedicarboxylic acid, 2,6-anthracene dicarboxylic acid, 4,4′-p-terphenylenedicarboxylic acid and 2,5-pyridine dicarboxylic acid. In addition, theremay also be used substituted products of these acids (for example,alkyl-substituted products such as 5-methyl isophthalic acid) as well asreactive derivatives of these acids (for example, alkyl esterderivatives such as dimethyl terephthalate and diethyl terephthalate).

Among these compounds, more preferred are terephthalic acid,2,6-naphthalene dicarboxylic acid and alkyl ester derivatives thereof,and still more preferred are terephthalic acid and alkyl esterderivatives thereof. These aromatic dicarboxylic acids may be used aloneor in combination of any two or more thereof. These aromaticdicarboxylic acids may also be used in combination with one or morekinds of aliphatic dicarboxylic acids such as adipic acid, azelaic acid,sebacic acid and dodecanedioic acid, and alicyclic dicarboxylic acidsuch as cyclohexanedicarboxylic acid.

Specific examples of the diol include aliphatic diols such as ethyleneglycol, 1,2-propylene glycol, 1,3-propanediol, 1,4-butanediol, neopentylglycol, 1,5-pentanediol, 1,6-hexanediol, decamethylene glycol and2,2-dimethyl-1,3-propanediol; alicyclic diols such as1,4-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, cyclohexanedioland trans- or cis-2,2,4,4-tetramethyl-1,3-cyclobutanediol; aromaticdiols such as p-xylylenediol, bisphenol A, tetrabromobisphenol A andtetrabromobisphenol A-bis(2-hydroxyethyl ether); and substitutedproducts thereof.

Among these diols, from the viewpoints of good thermal stability, impactresistance and rigidity, preferred are ethylene glycol, 1,3-propanediol,1,4-butanediol and 1,4-cyclohexanedimethanol, more preferred areethylene glycol, 1,3-propanediol and 1,4-butanediol, and most preferredis ethylene glycol. These diols may be used alone or in combination ofany two or more thereof. Further, as the diol component, the above diolsmay be used in combination with one or more long-chain diols having amolecular weight of 400 to 6,000 such as polyethylene glycol,poly-1,3-propylene glycol and polytetramethylene glycol, and both may becopolymerized with the dicarboxylic acid component.

Specific examples of the suitable thermoplastic polyester resin used asthe component A2 in the present invention include polyethyleneterephthalate resin (PET), polypropylene terephthalate resin (PPT),polybutylene terephthalate resin (PBT), polyhexylene terephthalateresin, polyethylene naphthalate resin (PEN), polybutylene naphthalateresin (PBN), poly(1,4-cyclohexanedimethylene terephthalate) resin (PCT)and polycyclohexylcyclohexylate (PCC). Among these thermoplasticpolyester resins, polyethylene terephthalate resin (PET), polypropyleneterephthalate resin (PPT) and polybutylene terephthalate resin (PBT) arepreferred from the viewpoints of good fluidity and impact resistance.More preferably, the polyethylene terephthalate resin (PET) is containedin an amount of not less than 10 parts by weight on the basis of 100parts by weight of the component A2.

Specific examples of the other thermoplastic polyester resin includepolypivalolactone resins and poly(ε-caprolactone) resins obtained byring-opening polymerization of lactones, and liquid crystal polymerscapable of forming a liquid crystal in a melted state (ThermotropicLiquid Crystal Polymer: TLCP). Specific examples of commerciallyavailable products of the liquid crystal polyester resins include “X7G”produced by Eastman Kodak Co., “Xyday” produced by Dartoco Corp.,“Econol” produced by Sumitomo Chemical Corp., and “Vectra” produced byCeraneed Corp.

Also, the thermoplastic polyester resin used in the present inventionmay have a branched structure by introducing a small amount of abranching agent thereinto. Examples of the branching agent includetrimesic acid, trimelittic acid, trimethylol ethane, trimethylol propaneand pentaerythritol, though not particularly limited thereto.

The polyethylene terephthalate resin especially preferably used as thecomponent A2 in the present invention is in the form of a saturatedpolyester or copolyester obtained by subjecting a dicarboxylic acidcomponent comprising terephthalic acid as a main component and a diolcomponent comprising ethylene glycol as a main component to condensationreaction, and is a thermoplastic polyester resin containing an ethyleneterephthalate unit as a repeating unit in an amount of preferably notless than 70 mol % and more preferably not less than 80 mol %.

Also, the polyethylene terephthalate resin may also contain diethyleneglycol as a copolymerized component which is a side reaction productproduced upon the polymerization. The amount of diethylene glycol in thepolyethylene terephthalate resin is preferably not less than 0.5 mol %,but usually not more than 6 mol % and preferably not more than 5 mol %on the basis of 100 mol % of a total amount of the diol component usedin the polymerization reaction.

The thermoplastic polyester resin (component A2) used in the presentinvention preferably has an intrinsic viscosity of 0.4 to 1.5 dL/g andmore preferably 0.5 to 1.3 dL/g. The intrinsic viscosity used herein ismeasured at 30° C. in a solvent containing phenol and tetrachloroethaneat a weight ratio of 50/50. When the intrinsic viscosity of thethermoplastic polyester resin is less than 0.4 dL/g, the resultant resincomposition tends to be deteriorated in impact resistance. When theintrinsic viscosity of the thermoplastic polyester resin is more than1.5 dL/g, the resultant resin composition tends to be deteriorated influidity.

The end carboxyl group content in the thermoplastic polyester resin ispreferably 5 to 50 μeq/g and more preferably 10 to 30 μeq/g. When theend carboxyl group content is less than 5 μeq/g, the resultant resincomposition tends to be deteriorated in impact resistance. When the endcarboxyl group content is more than 50 μeg/g, the resultant resincomposition tends to be insufficient in wet-heat resistance and thermalstability.

Further, as the thermoplastic polyester resin (component A2) used in thepresent invention, there may also be used not only the virgin resinmaterial, but also those thermoplastic polyester resins regenerated fromused resin products, i.e., so-called material-recycled thermoplasticpolyester resins. Examples of the used resin products mainly includecontainers, films, sheets and fibers. Among these products, morepreferred are containers such as PET bottles. Further, as theregenerated thermoplastic polyester resins, there may also be usednonconforming products and crushed or pulverized products obtained fromsprues and runners as well as pellets obtained by melting theseproducts.

Granular Talc (component B):

The granular talc used as the component B in the thermoplastic resincomposition according to the first aspect of the present invention(hereinafter occasionally referred to merely as the “component B”) isobtained by granulating a talc having an average particle size of 0.1 to10 μm into granules having a bulk density of 0.4 to 1.5 g/mL, and ischaracterized by such a particle size that a proportion of a 500 μm-meshscreen residue thereof is not less than 55% by weight.

The granular talc used in the present invention is a hydrous magnesiumsilicate having a layer structure which is represented by the chemicalformula: 4SiO₂.3MgO.H₂O and usually comprises 58 to 66% by weight ofSiO₂, 28 to 35% by weight of MgO and about 5% by weight of H₂O. Thegranular talc may also comprise, as the other trace components, 0.03 to1.2% by weight of Fe₂O₃, 0.05 to 1.5% by weight of Al₂O₃, 0.05 to 1.2%by weight of CaO, not more than 0.2% by weight of K₂O, not more than0.2% by weight of Na₂O, etc., and has a specific gravity of about 2.7.

The granular talc used in the present invention is a granulated productobtained by granulating a talc having an average particle size of 0.1 to10 μm (hereinafter occasionally referred to merely as the “raw materialtalc”). The average particle size of the raw material talc is preferably0.3 to 8 μm and more preferably 0.7 to 5 When using the raw materialtalc having an average particle size of not less than 0.1 μm, theresultant resin composition tends to be further enhanced in thermalstability, whereas when using the raw material talc having an averageparticle size of less than 10 the resultant resin composition tends tobe further enhanced in appearance of a molded product obtained therefromas well as rigidity. The average particle size used herein means D₅₀measured by a liquid phase precipitation method using X-raytransmission. The measurement of D₅₀ may be carried out, for example, byusing a Sedigraph particle size analyzer “Model 5100” manufactured byMicromeritics Instruments Corp.

In addition, the granular talc used in the present invention ispreferably subjected to surface treatment in order to enhance anaffinity to the resin as the component A. Specific examples of thesurface-treating agent include at least one compound selected from thegroup consisting of alcohols such as trimethylol ethane, trimethylolpropane and pentaerythritol; alkanol amines such as triethylamine;higher fatty acids such as stearic acid; fatty acid metal salts such ascalcium stearate and magnesium stearate; hydrocarbon-based lubricantssuch as polyethylene wax and liquid paraffin; basic amino acids such aslysine and alginine; polyglycerol and derivatives thereof; and couplingagents such as silane-based coupling agents, titanate-based couplingagents and aluminum-based coupling agents.

The granular talc used in the present invention has a bulk density of0.4 to 1.5 g/mL, preferably 0.5 to 1.3 g/mL and more preferably 0.6 to1.1 g/mL. When using the granular talc having a bulk density of not lessthan 0.4 g/mL, the resultant resin composition tends to be furtherenhanced in extrusion moldability, flame retardancy, impact resistanceand thermal stability, whereas when using the granular talc having abulk density of less than 1.5 g/mL, the resultant resin compositiontends to be further enhanced in appearance of a molded product obtainedtherefrom as well as impact resistance.

The bulk density used herein is the value measured by the followingmethod.

(1) The granular talc is placed on a screen having a mesh size of 1.4 mmand allowed to pass therethrough while lightly uniformly sweeping with abrush.

(2) The granular talc passed through the screen is charged into areceptacle fitted to a bulk density measuring apparatus prescribed inJIS K5101 until heaping up the receptacle with the granular talc.

(3) An upper portion of the granular talc heaped up in the receptacle iswiped off using a spatula through an inlet of the receptacle to measurea weight of the granular talc in the receptacle and calculate a bulkdensity of the granular talc according to the following formula.

Bulk density (g/mL)=(weight (g) of granular talc inreceptacle)/(capacity (mL) of receptacle)

The granular talc used in the present invention has such a particle sizethat a proportion of a 500 μm-mesh screen residue thereof is not lessthan 55% by weight, preferably not less than 60% by weight, morepreferably not less than 70% by weight and still more preferably notless than 90% by weight. When using the granular talc having such aparticle size in which a proportion of a 500 μm-mesh screen residuethereof is not less than 55% by weight, the resultant resin compositionof the present invention tends to be further enhanced in flameretardancy and thermal stability.

The particle size of the granular talc is the value measured by thefollowing method according to JIS 28801.

(1) The granular talc is placed on a screen having a mesh size of 2 mmand allowed to pass therethrough while lightly uniformly sweeping with abrush.

(2) The granular talc passed through the screen is fully charged into a200 mL beaker, and subjected to sample reduction using a samplereduction device “1305 No. 6” (groove width: 6 mm) manufactured byFuruta Seisakusho Co., Ltd., until the amount of the talc is reduced toabout 30 mL.

(3) Using a screen having a mesh size of 500 the granular talc thussubjected to sample reduction is sieved therethrough to determine aweight of the granular talc not passed through the 500 μm-mesh screen(screen residue; oversize) and calculate a proportion of the non-passedgranular talc by dividing the thus measured weight by a whole weight ofthe granular talc. Meanwhile, the sieving procedure is carried out at afrequency of 120 cycles/sec for 10 min using an electromagnetic sieve“M-100 Type” manufactured by Tsutsui Rikagaku Kiki Co., Ltd.

The method for producing the granular talc used in the present inventionfrom the raw material talc (granulation method) is optional, and thegranular talc may be produced by any optional known methods. Morespecifically, for example, the granular talc is preferably a granulatedproduct obtained by using a binder from the viewpoints of good flameretardancy, thermal stability, impact resistance and rigidity of theresultant resin composition.

The binder used upon producing the granular talc used in the presentinvention is preferably such a material which has a high granulatingability with the raw material talc, is colorless or near white color,and is inert and stable without causing deterioration in properties ofthe obtained resin molded product. Specific examples of the binderinclude clay minerals having a high caking property in a wet state suchas bentonite, colloidal silica, gypsum, water-soluble polymers, waxes,higher fatty acids and resin powders. Among these binders, from theviewpoints of good thermal stability, impact resistance and rigidity ofthe resultant resin composition, preferred are clay minerals andwater-soluble polymers, and more preferred are water-soluble polymers.

Examples of the water-soluble polymers include water-soluble polyesterresins, polyvinyl alcohol, polyvinyl pyrrolidone, polyethyleneoxide,poly(sodium acrylate), sodium alginate, agar, polysaccharides (e.g.,cellulose-based derivatives such as methyl cellulose, ethyl cellulose,hydroxyethyl cellulose, hydroxypropyl cellulose and sodium carboxymethylcellulose, or starches), and proteins (such as gelatin and glues).

Among these water-soluble polymers, water-soluble polyester resins,polysaccharides and proteins are preferred because of a high cakingproperty and a high adsorptivity to the talc. In particular, among them,from the viewpoints of good flame retardancy and impact resistance ofthe resultant resin composition, more preferred are water-solublepolyester resins, sodium carboxymethyl cellulose (hereinafteroccasionally referred to merely as “CMC”), and gelatin, and still morepreferred are CMC and water-soluble polyester resins.

In the present invention, the water-soluble polyester resins preferablyused as the binder are in the form of a copolymer obtained by subjectinga dicarboxylic acid component comprising a dicarboxylic acid or areactive derivative thereof, a diol component comprising a diol or anester derivative thereof and a water-solubility imparting component asmain raw materials, to condensation reaction, which exhibits a highsolubility in water. The water solubility of the copolymer in water maybe appropriately determined and may be controlled by varying a contentof the water-solubility imparting component.

The dicarboxylic acid used as the raw material of the water-solublepolyester resins may be in the form of either an aromatic dicarboxylicacid or an aliphatic dicarboxylic acid. From the viewpoints of a goodheat resistance of the resultant resin composition, etc., the aromaticdicarboxylic acid is preferred. Specific examples of the aromaticdicarboxylic acid include terephthalic acid, isophthalic acid,orthophthalic acid, 1,5-naphthalenedicarboxylic acid,2,6-naphthalenedicarboxylic acid, 4,4′-biphenyl dicarboxylic acid,4,4′-biphenylether dicarboxylic acid, 4,4′-biphenylmethane dicarboxylicacid, 4,4′-biphenylsulfone dicarboxylic acid,4,4′-biphenylisopropylidene dicarboxylic acid,1,2-bis(phenoxy)ethane-4,4′-dicarboxylic acid, 2,5-anthracenedicarboxylic acid, 2,6-anthracene dicarboxylic acid, 4,4′-p-terphenylenedicarboxylic acid, and 2,5-pyridine dicarboxylic acid. Further, theremay also be used substituted products of these acids (for example,alkyl-substituted products such as 5-methylisophthalic acid) or reactivederivatives of these acids (for example, alkyl ester derivatives such asdimethyl terephthalate and diethyl terephthalate).

Among these aromatic dicarboxylic acids, preferred are terephthalicacid, isophthalic acid, 2,6-naphthalene dicarboxylic acid and alkylester derivatives of these acids. These aromatic dicarboxylic acids maybe use alone or in combination of any two or more thereof. In addition,the aromatic dicarboxylic acids may be used in combination with one ormore acids selected from the group consisting of aliphatic dicarboxylicacids such as adipic acid, azelaic acid, sebacic acid, dodecanedioicacid, and alicyclic dicarboxylic acids such as cyclohexane dicarboxylicacid.

Examples of the diol used as the raw material of the water-solublepolyester resins include aliphatic diols such as ethylene glycol,1,2-propylene glycol, 1,3-propanediol, 1,4-butanediol, neopentyl glycol,1,5-pentanediol, 1,6-hexanediol, decamethylene glycol and2,2-dimethyl-1,3-propanediol; alicyclic diols such as 1,4-cyclohexanedimethanol, 1,3-cyclohexane dimethanol, cyclohexanediol and trans- orcis-2,2,4,4-tetramethyl-1,3-cyclobutanediol; aromatic diols such asp-xylylenediol, bisphenol A, tetrabromobisphenol A andtetrabromobisphenol A-bis(2-hydroxyethyl ether); and substituted productof these compounds.

Among these diols, from the viewpoints of a good heat resistance of theresultant resin composition, preferred are ethylene glycol,1,3-propanediol, 1,4-butanediol and 1,4-cyclohexane dimethanol, morepreferred are ethylene glycol, 1,3-propanediol and 1,4-butanediol, andmost preferred is ethylene glycol. These diols may be used alone or incombination of any two or more thereof. Further, as the diol component,one or more long-chain diol having a molecular weight of 400 to 6000such as polyethylene glycol, poly-1,3-propylene glycol andpolytetramethylene glycol, may be used in combination with the abovediols, and both may be copolymerized with the dicarboxylic acidcomponent.

Examples of the water solubility imparting component used as the rawmaterial of the water-soluble polyester resins include dicarboxylicacids containing a metal sulfonate group, and polyethylene glycol. Amongthese compounds, from the viewpoint of a good heat resistance, preferredare dicarboxylic acids containing a metal sulfonate group.

Examples of the dicarboxylic acids containing a metal sulfonate groupinclude alkali metal salts such as sodium salts and potassium salts of5-sulfo-isophthalic acid, 2-sulfo-isophthalic acid, 4-sulfo-isophthalicacid, sulfo-terephthalic acid, 4-sulfo-naphthalene-2,6-dicarboxylicacid, etc., and ester-forming derivatives of these acids. Among thesecompounds, from the viewpoint of a high water solubility, preferred aresodium 5-sulfo-isophthalate and ester derivatives thereof.

When the content of the dicarboxylic acid containing a metal sulfonategroup is too small, the resultant polyester resins tend to beinsufficient in water solubility. On the other hand, when the content ofthe dicarboxylic acid containing a metal sulfonate group is too large,the resultant water-soluble polyester resins tend to be insufficient inheat resistance. Therefore, the content of the dicarboxylic acidcontaining a metal sulfonate group in the water-soluble polyester resinsis preferably 1 to 40 mol % and more preferably 5 to 35 mol % on thebasis of the whole carboxylic acid component as the raw material of thewater-soluble polyester resins.

Specific examples of the preferred water-soluble polyester resins as thebinder for the granular inorganic filler (component B) used in thepresent invention include copolymers obtained from terephthalic acid,ethylene glycol and sodium 5-sulfo-isophthalate. Examples ofcommercially available products of the water-soluble polyester resinsinclude “PLUSCOAT Z-221”,“PLUSCOAT Z-561” and “PLUSCOAT Z-446” allproduced by Go-Oh Kagaku Kogyo Co., Ltd., etc.

Next, examples of the CMC preferably used as the binder in the presentinvention include those obtained by treating natural pulp as a rawmaterial with sodium hydroxide to produce an alkali cellulose, and thenetherifying the resultant alkali cellulose with monochloroacetic acid.The CMC may be produced by either a solvent method or an aqueous mediummethod. The properties of the CMC may vary depending upon thepolymerization degree and etherification degree calculated fromanhydrous glycol units therein. The CMC preferably used in the presentinvention has an average polymerization degree of 100 to 500, anetherification degree of 0.5 to 1.7 and a viscosity of a 7.1% aqueoussolution of 10 to 500 mPa·s (as measured at 25° C. using a B-typeviscometer) from the viewpoints of a good solubility in water and asuitable viscosity of the obtained aqueous solution. When theseproperties are out of the above specified ranges, the CMC tends tosuffer from problems from the viewpoint of a granulating ability of thetalc.

The content of the binder in the granular talc used in the presentinvention is preferably 0.01 to 5% by weight, more preferably 0.05 to3.5% by weight and still more preferably 0.1 to 3% by weight on thebasis of 100% by weight as the total amount of the granular talc. Whenthe content of the binder is not less than 0.01% by weight, the granulartalc tends to be hardly broken, and the resultant resin compositiontends to be further enhanced in flame retardancy, thermal stability andimpact resistance. On the other hand, when the content of the binder isless than 5% by weight, the granular talc tends to exhibit a gooddispersibility in the resin composition, and the resultant resincomposition tends to be further enhanced in appearance of a moldedproduct obtained therefrom as well as impact resistance.

The method for producing the granular talc used in the present inventionis optional and is not particularly limited. In order to enhance akneading property between the talc and binder, impart a good plasticityto the obtained kneaded material upon production of the granules,realize a facilitated production, reduce abrasion in a granulator, andfurther control a hardness of the resultant granules, it is preferred toadd a wetting agent to the talc and binder. Usually, the wetting agentis added to the talc and binder, if required, together with otheradditives such as a dispersant, and these components are mixed with eachother while stirring using a mixer such as a Henschel mixer and asuper-mixer, thereby obtaining a mixture of these components.

The thus obtained mixture is kneaded using a screw-type extruder such asa single-screw extruder and a twin-screw extruder, and then extrudedtherefrom into strands. The extruded strands are cut and granulated, andthen dried using a fluidized type dryer or a band heater, therebyobtaining the granular talc. After drying, the resultant granules may besubjected to classification.

The size and shape of the granular talc are not particularly limited,and the granular talc may be of any shape such as a bar shape, acylindrical shape, a needle-like shape, a spherical shape, a granularshape, a flake-like shape and an amorphous shape, and may be producedwith various shapes by controlling molding conditions and granulatingconditions depending upon the applications thereof. For example, in thecase where the bar-shaped or cylindrical particles are to be produced,the axis diameter of these particles may be appropriately adjusted byvarying a mesh size of a screen used in a screen-type extrusion moldingmachine, and the thus molded product may be granulated and then cut intoa desired axis length.

The size of the granular talc is not particularly limited as long as thebulk density and particle size thereof lie within the above specifiedranges. However, when dispersed in a melt kneader or a molding machine,it is more advantageous that the size of the granular talc is smallerthan that of resin pellets used upon melt-kneading or molding. Forexample, the bar-shaped or cylindrical granular talc preferably has anaverage axis diameter of 0.2 to 6 mm and an average axis length of 2 to6 mm and more preferably a ratio of an average axis diameter to anaverage axis length of 1:0.5 to 1:2.

Examples of the lubricant used in the present invention include water,organic solvents, etc. Among these lubricants, from the viewpoints of alow price and a good working efficiency, preferred is water which may bea mixture with alcohols. In addition, a binder may be previouslydissolved or suspended in water as a wetting agent. Further, otheradditives required for forming granules such as, for example, adispersant, a surfactant, various additives for synthetic resins, dyes,etc., may be dissolved or suspended in water in order to further enhancea uniformity of the resultant granules. Also, when using water as thelubricant, the water content in the granular talc is preferablycontrolled to not more than 1% and more preferably not more than 0.3% bydrying the granular talc using a fluidized bed dryer, etc., to removewater therefrom. The drying temperature is suitably 80 to 150° C. andpreferably 80 to 110° C.

The amount of the lubricant blended is 10 to 150 parts by weight,preferably 15 to 100 parts by weight and more preferably 20 to 60 partsby weight on the basis of 100 parts by weight of a total amount of thetalc and binder. When the amount of the lubricant blended is less than10 parts by weight, the effect of addition of the lubricant tends to beinsufficient, whereas when the amount of the lubricant blended is morethan 150 parts by weight, excessive time and energy tend to be requiredfor removal of the lubricant, resulting in disadvantageous process.

In the present invention, it is preferred that a dispersant is blendedin the granular talc in an amount of 0.05 to 2.0% by weight andpreferably 0.1 to 0.5% by weight, because the granular talc can beenhanced in dispersibility in a molded product obtained from the resincomposition. The dispersant used in the present invention may begenerally known ones. Examples of the dispersant include theabove-mentioned alcohols, alkanol amines, organic silicone-basedcompounds, higher fatty acids, fatty acid metal salts, hydrocarbon-basedlubricants, basic amino acids, polyglycerol, and derivatives thereof. Inthe present invention, there may be used one or more dispersantsselected from these compounds. In addition, the above surface-treatedtalc may be mixed with the dispersant and then granulated.

Further, in addition to the dispersant, various other additives may beadded, if required, to the granular talc used in the present inventionunless the addition of these additives adversely affects the features oreffects of the present invention. Specific examples of the otheradditives include various antioxidants such as hindered phenol-basedcompounds, various heat stabilizers such as phosphite-based compounds,various ultraviolet absorbers such as benzotriazole-based compound,benzophenone-based compounds and triazine-based compounds, various flameretardants such as phosphate-based compounds, silicone-based compoundsand metal salt-based compounds, various release agents such as olefinwaxes and fatty acid ester-based compounds, antibacterial agents andmildew-proof agents such as phenol-based compounds, antistatic agentssuch as anionic, cationic or nonionic compounds, colorants, fillersother than talc, light stabilizers, plasticizers, and foaming agents.These additives may also be used in the form of a blended mixture ofplural kinds thereof.

Rubber Polymer (Component C):

The thermoplastic resin composition according to the first aspect of thepresent invention preferably further comprises a rubber polymer as acomponent C (hereinafter occasionally referred to merely as the“component C”) for the purpose of improving an impact resistance of theresin composition. The rubber polymer used in the present invention hasa glass transition temperature of not higher than 0° C., in particular,not higher than −20° C., and also involves such a polymer obtained bycopolymerizing the rubber polymer with a monomer componentcopolymerizable therewith. The component C used in the present inventionmay be selected from optional known rubber polymers which are generallyblended in aromatic polycarbonate resin compositions, etc., to improvemechanical properties thereof.

Examples of the rubber polymer include polybutadiene, polyisoprene,diene-based copolymers (such as styrene-butadiene copolymers,acrylonitrile-butadiene copolymers and acryl-butadiene rubbers),copolymers of ethylene and α-olefin (such as ethylene-propylenecopolymers, ethylene-butene copolymers and ethylene-octene copolymers),copolymers of ethylene and unsaturated carboxylic acid ester (such asethylene-methacrylate copolymers and ethylene-butyl acrylatecopolymers), copolymers of ethylene and an aliphatic vinyl compound,terpolymers of ethylene, propylene and a non-conjugated diene, acrylicrubbers (such as poly(butyl acrylate), poly(2-ethylhexyl acrylate) andbutyl acrylate-2-ethylhexyl acrylate copolymers), and silicone-basedrubbers (such as polyorganosiloxane rubbers and IPN-type compositerubbers comprising polyorganosiloxane rubber and poly(alkyl(meth)acrylate) rubber). These rubber polymers may be used alone or incombination of any two or more thereof. Meanwhile, the term“(meth)acrylate” means both “acrylate” and “methacrylate”, and thebelow-mentioned term “(meth)acrylic acid” means both “acrylic acid” and“methacrylic acid”.

Examples of the suitable monomer component which may be optionallycopolymerized with the rubber polymer according to the requirements,include aromatic vinyl compounds, cyanided vinyl compounds,(meth)acrylate compounds, and (meth)acrylic acid compounds. Examples ofthe other monomer component include epoxy group-containing(meth)acrylate compounds such as glycidyl (meth)acrylate; maleimidecompounds such as maleimide, N-methyl maleimide and N-phenyl maleimide;and α,β-unsaturated carboxylic acid compounds such as maleic acid,phthalic acid and itaconic acid, and anhydrides of these acids such asmaleic anhydride. These monomer components may also used alone or incombination of any two or more thereof.

In order to improve an impact resistance of the thermoplastic resincomposition of the present invention, a core/shell type graft copolymeris preferably used as the rubber polymer (component C). Among them,especially preferred are those core/shell type graft copolymerscomprising a core layer formed from at least one rubber polymer selectedfrom the group consisting of butadiene-containing rubbers, butylacrylate-containing rubbers, 2-ethylhexyl acrylate-containing rubbersand silicone-based rubbers, and a shell layer formed around the corelayer by copolymerizing at least one monomer component selected from thegroup consisting of acrylates, methacrylates and aromatic vinylcompounds. Specific examples of the core/shell type graft copolymerinclude methyl methacrylate-butadiene-styrene polymers (MBS), methylmethacrylate-acrylonitrile-butadiene-styrene polymers (MABS), methylmethacrylate-butadiene polymers (MB), methyl methacrylate-acrylic rubberpolymers (MA), methyl methacrylate-acrylic/butadiene rubber copolymers,methyl methacrylate-acrylic/butadiene rubber-styrene copolymers, andmethyl methacrylate-(acryl/silicone IPN (interpenetrating polymernetwork) rubber) polymers. These rubber polymers may be used alone or incombination of any two or more thereof.

Examples of commercially available products of the core/shell type graftcopolymer include EXL series such as PARALOID EXL2315, EXL2602 andEXL2603, KM series such as KM330 and KMM336P, and KCZ series such asKCZ201, all produced by Rohm & Haas Japan Co., Ltd., and METHABlENES-2001 and SRK-200 both produced by Mitsubishi Rayon Co., Ltd.

Specific examples of the other rubber polymers obtained bycopolymerizing the rubber polymer with the monomer componentcopolymerizable therewith include polybutadiene rubbers,styrene-butadiene copolymers (SBR), styrene-butadiene-styrene blockcopolymers (SBS), styrene-ethylene/butylene-styrene block copolymers(SEBS), styrene-ethylene/propylene-styrene block copolymers (SEPS),ethylene-ethyl acrylate copolymers (EEA) and ethylene-methyl acrylatecopolymers (EMA).

Contents:

In the thermoplastic resin composition according to the first aspect ofthe present invention, the contents of the constituting components A toC are as follows. That is, the content of the resin component (componentA) comprising 10 to 90% by weight of the aromatic polycarbonate resin(component A1) and the thermoplastic resin other than the aromaticpolycarbonate resin (component A2) with the proviso that the totalcontent of the components A1 and A2 is 100% by weight, is 40 to 99 partsby weight; the content of the granular talc (component B) is 1 to 60parts by weight; and the content of the rubber polymer (component C) is0 to 35 parts by weight.

The content ratio of the component A1 to the component A2 is controlledsuch that the content of the component A1 is 10 to 90% by weight,preferably 25 to 90% by weight, more preferably 50 to 85% by weight andstill more preferably 61 to 80% by weight on the basis of 100% by weightas a total amount of the components A1 and A2; and the content of thecomponent A2 is 90 to 10% by weight, preferably 75 to 10% by weight,more preferably 50 to 15% by weight and still more preferably 39 to 20%by weight on the basis of 100% by weight as a total amount of thecomponents A1 and A2. When the content of the component A1 is less than10% by weight, the resultant resin composition tends to be insufficientin impact resistance, whereas when the content of the component A1 ismore than 90% by weight, the resultant resin composition tends to bedeteriorated in thermal stability, fluidity and chemical resistance.

The content of the component B is 1 to 60 parts by weight, preferably 3to 50 parts by weight and more preferably 5 to 35 parts by weight on thebasis of 100 parts by weight of a total amount of the components A, Band C. When the content of the component B is less than 1 part byweight, the resultant resin composition tends to be insufficient inrigidity, whereas when the content of the component B is more than 60parts by weight, the resultant resin composition tends to bedeteriorated in impact resistance and thermal stability.

Also, the content of the component C is 0 to 35 parts by weight,preferably 1 to 30 parts by weight and more preferably 3 to 25 parts byweight on the basis of 100 parts by weight of a total amount of thecomponents A, B and C. When the component C is blended in an amount ofnot less than 1 part by weight, the resultant resin composition tends toexhibit a good impact resistance. Whereas, when the content of thecomponent C is more than 35 parts by weight, the resultant resincomposition tends to be deteriorated in thermal stability and rigidity.

Phosphorus-based Compound (Component D):

The thermoplastic resin composition according to the first aspect of thepresent invention preferably further comprises a phosphorus-basedcompound as a component D (hereinafter occasionally referred to merelyas the “component D”) for the purpose of improving a thermal stabilityand heat resistance of the resin composition, unless the addition of thecomponent D adversely affects the aimed effects of the presentinvention. As the phosphorus-based compound, there may be used optionalknown phosphorus-based compounds. Specific examples of thephosphorus-based compound include oxo acids of phosphorus such asphosphoric acid, phosphonic acid, phosphorous acid, phosphinic acid andpolyphosphoric acid; acid pyrophosphoric acid metal salts such as acidsodium pyrophosphate, acid potassium pyrophosphate and acid calciumpyrophosphate; phosphates of metals of Group 1 or Group 2B such aspotassium phosphate, sodium phosphate, cesium phosphate and zincphosphate; organic phosphate compounds; organic phosphite compounds; andorganic phosphonite compounds. Among these phosphorus-based compounds,preferred are the organic phosphate compounds represented by thefollowing general formula (I) and/or the organic phosphite compoundsrepresented by the following general formula (II).

O═P(OH)_(m)(OR)_(3-m)  (I)

wherein R is an alkyl group or an aryl group and the plural R groups, ifany, may be the same or different; and m is an integer of 0 to 2,

wherein R′ is an alkyl group or an aryl group and the R′ groups may bethe same or different.

In the general formula (I), R is preferably an alkyl group having 1 to30 carbon atoms or an aryl group having 6 to 30 carbon atoms, and morepreferably an alkyl group having 2 to 25 carbon atoms; and m ispreferably 1 and/or 2.

In the general formula (II), R′ is preferably an alkyl group having 1 to30 carbon atoms or an aryl group having 6 to 30 carbon atoms. Specificexamples of the phosphite represented by the above general formula (II)include distearyl pentaerythritol diphosphite,bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite andbis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite.

The content of the phosphorus-based compound is preferably 0.001 to 1part by weight, more preferably 0.01 to 0.7 part by weight and stillmore preferably 0.03 to 0.5 part by weight on the basis of 100 parts byweight of a total amount of the components A, B and C.

Other Components:

The thermoplastic resin composition of the present invention may alsocontain various additives for resins, if required, unless the additionof these additives adversely affects the aimed effects of the presentinvention. Examples of the additives for resins include antioxidants,release agents, inorganic fillers other than talc, ultravioletabsorbers, dyes and pigments, flame retardants, dropping inhibitors,antistatic agents, antifogging agents, lubricants, anti-blocking agents,fluidity improvers, plasticizers, dispersants and antibacterial agents.These additives may be used in combination of any two or more thereof.Typical examples of the suitable additives usable in the thermoplasticresin composition of the present invention are more specificallyexplained below.

Examples of the antioxidant include hindered phenol-based antioxidants.Specific examples of the hindered phenol-based antioxidants includepentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,thiodiethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],N,N′-hexane-1,6-diylbis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionamide],2,4-dimethyl-6-(1-methylpentadecyl)phenol,diethyl[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]phosphate,3,3′,3″,5,5′,5″-hexa-tert-butyl-a,a′,a″-(mesitylene-2,4,6-triyl)tri-p-cresol,4,6-bis(octylthiomethyl)-o-cresol,ethylenebis(oxyethylene)bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)propionate],hexamethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-1,3,5-triazine-2,4,6-(1H,3H, 5H)-trione and2,6-di-tert-butyl-4-(4,6-bis(octylthio)-1,3,5-triazine-2-ylamino)phenol.These hindered phenol-based antioxidants may be used in combination ofany two or more thereof.

Among these hindered phenol-based antioxidants, preferred arepentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] andoctadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate. The above twophenol-based antioxidants are respectively commercially available undertradenames “IRGANOX 1010” and “IRGANOX 1076” from Ciba SpecialtyChemicals, Corp.

The content of the antioxidant in the resin composition is usually 0.001to 1 part by weight and preferably 0.01 to 0.5 part by weight on thebasis of 100 parts by weight of a total amount of the components A, Band C. When the content of the antioxidant is less than 0.001 part byweight, the effect of the antioxidant added tends to be insufficient.Whereas, when the content of the antioxidant is more than 1 part byweight, the effect of the antioxidant tends to be no longer increased,resulting in uneconomical process.

As the release agent, there may be used at least one compound selectedfrom the group consisting of aliphatic carboxylic acids, esters ofaliphatic carboxylic acids and alcohols, aliphatic hydrocarbon compoundshaving a number-average molecular weight of 200 to 15000, andpolysiloxane-based silicone oils.

Examples of the aliphatic carboxylic acids include saturated orunsaturated aliphatic mono-, di- or tri-carboxylic acids. The aliphaticcarboxylic acids used herein also involve alicyclic carboxylic acids.Among them, the aliphatic carboxylic acids are preferably mono- ordi-carboxylic acids having 6 to 36 carbon atoms and more preferablyaliphatic saturated monocarboxylic acids having 6 to 36 carbon atoms.Specific examples of the aliphatic carboxylic acids include palmiticacid, stearic acid, caproic acid, capric acid, lauric acid, arachicacid, behenic acid, lignoceric acid, cerotic acid, melissic acid,tetratriacontanoic acid, montanoic acid, adipic acid and azelaic acid.

As the aliphatic carboxylic acids forming the esters of aliphaticcarboxylic acids and alcohols, there may be used the same aliphaticcarboxylic acids as described above. Examples of the alcohols includesaturated or unsaturated monohydric alcohols and saturated orunsaturated polyhydric alcohols. These alcohols may contain asubstituent group such as a fluorine atom and an aryl group. Inparticular, among these alcohols, preferred are monohydric or polyhydricsaturated alcohols having not more than 30 carbon atoms, and morepreferred are aliphatic saturated monohydric alcohols or polyhydricalcohols having not more than 30 carbon atoms.

The term “aliphatic” used herein also involves alicyclic compounds.Specific examples of the alcohols include octanol, decanol, dodecanol,stearyl alcohol, behenyl alcohol, ethylene glycol, diethylene glycol,glycerol, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentylglycol, ditrimethylol propane and dipentaerythritol.

Meanwhile, the above ester compounds may contain the aliphaticcarboxylic acids and the alcohols as impurities, and may be in the formof a mixture containing a plurality of these compounds.

Specific examples of the esters of the aliphatic carboxylic acids andalcohols include beeswax (mixture comprising myricyl palmitate as a maincomponent), stearyl stearate, behenyl behenate, stearyl behenate,glycerol monopalmitate, glycerol monostearate, glycerol distearate,glycerol tristearate, pentaerythritol monopalmitate, pentaerythritolmonostearate, pentaerythritol distearate, pentaerythritol tristearateand pentaerythritol tetrastearate.

Examples of the aliphatic hydrocarbons having a number-average molecularweight of 200 to 15000 include liquid paraffins, paraffin waxes, microwaxes, polyethylene waxes, Fischer-Tropsch waxes and α-olefin oligomershaving 3 to 12 carbon atoms. The aliphatic hydrocarbons used thereinalso involve alicyclic hydrocarbons. In addition, these hydrocarboncompounds may be partially oxidized. Among these aliphatic hydrocarbons,preferred are paraffin waxes, polyethylene waxes and partially oxidizedpolyethylene waxes, and more preferred are paraffin waxes andpolyethylene waxes. The number-average molecular weight of the aliphatichydrocarbons is preferably 200 to 5000. These aliphatic hydrocarbons maybe in the form of a single substance or a mixture of various substanceswhich are different in components and molecular weight from each otheras long as the content of the main component lies within theabove-specified range.

Examples of the polysiloxane-based silicone oils include dimethylsilicone oils, phenylmethyl silicone oils, diphenyl silicone oils andfluorinated alkyl silicones. These silicone oils may be used incombination of any two or more thereof.

The content of the release agent in the resin composition is usually0.001 to 2 parts by weight and preferably 0.01 to 1 part by weight onthe basis of 100 parts by weight of a total amount of the components A,B and C. When the content of the release agent is less than 0.001 partby weight, the releasing effect tends to be insufficient, whereas whenthe content of the release agent is more than 2 parts by weight, theretend to arise problems such as deteriorated hydrolysis resistance of theresultant resin composition and contamination of a mold used uponinjection molding.

Specific examples of the inorganic fillers other than talc includeglass-based fillers such as glass fiber (chopped strand), glass shortfiber (milled fiber), glass flakes and glass beads; carbon-based fillerssuch as carbon fiber, carbon short fiber, carbon nanotube and graphite;whiskers such as potassium titanate whiskers and aluminum boratewhiskers; silicate compounds such as mica, wollastonite, kaolinite,zonotlite, sepiolite, attapulgite, montmorillonite, bentonite andsmectite; silica; alumina; and calcium carbonate. Among these inorganicfillers, preferred are mica, wollastonite and kaolinite. These inorganicfilers may be used in combination of any two or more thereof.

The content of the inorganic filler in the resin composition is usually1 to 60 parts by weight, preferably 3 to 50 parts by weight and morepreferably 5 to 30 parts by weight on the basis of 100 parts by weightof a total amount of the components A, B and C. When the content of theinorganic filler is less than 1 part by weight, the reinforcing effecttends to be insufficient, whereas when the content of the inorganicfiller is more than 60 parts by weight, the resultant resin compositiontends to be deteriorated in appearance and impact resistance and tendsto be insufficient in fluidity.

Specific examples of the ultraviolet absorbers include inorganicultraviolet absorbers such as cerium oxide and zinc oxide; and organicultraviolet absorbers such as benzotriazole compounds, benzophenonecompounds and triazine compounds. Among these ultraviolet absorbers,preferred are the organic ultraviolet absorbers, and more preferred isat least one compound selected from the group consisting ofbenzotriazole compounds,2-(4,6-diphenyl-1,3,5-triazine-2-yl)-5-[(hexyl)oxy]-phenol,2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine-2-yl)-5-(octyloxy)-phenol,2,2′-(1,4-phenylene)bis[4H-3,1-benzoxazine-4-one], and[(4-methoxyphenyl)-methylene]-propanedioic acid dimethyl ester.

Specific examples of the benzotriazole compounds include a condensedproduct ofmethyl-3-[3-tert-butyl-5-(2H-benzotriazole-2-yl)-4-hydroxyphenyl]propionateand polyethylene glycol. Specific examples of the other benzotriazolecompounds include 2-bis(5-methyl-2-hydroxyphenyl)benzotriazole,2-(3,5-di-tert-butyl-2-hydroxyphenyl)benzotriazole,2-(3′,5′-di-tert-butyl-2′-hydroxyphenyl)-5-chlorobenzotriazole,2-(3-tert-butyl-5-methyl-2-hydroxyphenyl)-5-chlorobenzotriazole,2-(2′-hydroxy-5′-tert-octylphenyl)benzotriazole,2-(3,5-di-tert-amyl-2-hydroxyphenyl)benzotriazole,2-[2-hydroxy-3,5-bis(α,α-dimethylbenzyl)phenyl]-2H-benzotriazole,2,2′-methylenebis[4-(1,1,3,3-tetramethylbutyl)-6-(2N-benzotriazole-2-yl)phenol],and a condensed product of[methyl-3-[3-tert-butyl-5-(2H-benzotriazole-2-yl)-4-hydroxyphenyl]propionateand polyethylene glycol. These benzotriazole compounds may be used incombination of any two or more thereof.

Among these benzotriazole compounds, preferred are2-(2′-hydroxy-5′-tert-octylphenyl)benzotriazole,2-[2-hydroxy-3,5-bis(a,α-dimethylbenzyl)phenyl]-2H-benzotriazole,2-(4,6-diphenyl-1,3,5-triazine-2-yl)-5-[(hexyl)oxy]-phenol,2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine-2-yl)-5-(octyloxy)-phenoland2,2′-methylene-bis[4-(1,1,3,3-tetramethylbutyl)-6-(2N-benzotriazole-2-yl)phenol].

The content of the ultraviolet absorber in the resin composition isusually 0.01 to 3 parts by weight and preferably 0.1 to 1 part by weighton the basis of 100 parts by weight of a total amount of the componentsA, B and C. When the content of the ultraviolet absorber is less than0.001 part by weight, the effect of improving a weather resistance ofthe resin composition tends to be insufficient, whereas when the contentof the ultraviolet absorber is more than 3 parts by weight, there tendto arise problems such as mold deposits.

As the dye and pigment, there may be used inorganic pigments, organicpigments and organic dyes. Examples of the inorganic pigments includecarbon blacks; sulfide-based pigments such as cadmium red and cadmiumyellow; silicate-based pigments such as ultramarine blue; oxide-basedpigments such as titanium oxide, zinc white, red iron oxide, chromiumoxide, iron black, titanium yellow, zinc-iron-based brown,titanium/cobalt-based green, cobalt green, cobalt blue,copper/chromium-based black and copper/iron-based black; chromate-basedpigments such as chrome yellow and molybdate orange; andferrocyanide-based pigments such as Prussian blue. Examples of theorganic pigment and organic dyes include phthalocyanine-based dyes andpigments such as copper phthalocyanine blue and copper phthalocyaninegreen; azo-based dyes and pigments such as nickel azo yellow; condensedpolycyclic dyes and pigments such as thioindigo-based compounds,perynone-based compounds, perylene-based compounds, quinacridone-basedcompounds, dioxazine-based compounds, isoindolinone-based compounds andquinaphthalone-based compounds; and anthraquinone-based, heterocyclicand methyl-based dyes and pigments. These dyes and pigments may be usedin combination of any two or more thereof. Among these dyes andpigments, from the viewpoint of a good thermal stability, preferred aretitanium oxide, carbon blacks, cyanine-based compounds, quinoline-basedcompounds, anthraquinone-based compounds and phthalocyanine-basedcompounds.

The content of the dye and pigment in the resin composition is usuallynot more than 5 parts by weight, preferably not more than 3 parts byweight and more preferably not more than 2 parts by weight on the basisof 100 parts by weight of a total amount of the components A, B and C.When the content of the dye and pigment is more than 5 parts by weight,the resultant resin composition tend to be insufficient in impactresistance.

Examples of the flame retardant include halogen-based flame retardantssuch as polycarbonates of halogenated bisphenol A, brominatedbisphenol-based epoxy resins, brominated bisphenol-based phenoxy resinsand brominated polystyrenes; phosphate-based flame retardants; organicmetal salt-based flame retardants such as dipotassium diphenylsulfone-3,3′-disulfonate, potassium diphenyl sulfone-3-sulfonate andpotassium perfluorobutane sulfonate; and polyorganosiloxane-based flameretardants. Among these flame retardants, preferred are phosphate-basedflame retardants.

Specific examples of the phosphate-based flame retardants includetriphenyl phosphate, resorcinol-bis(dixylenylphosphate),hydroquinone-bis(dixylenylphosphate),4,4′-bisphenol-bis(dixylenylphosphate), bisphenolA-bis(dixylenylphosphate), resorcinol-bis(diphenylphosphate),hydroquinone-bis(diphenylphosphate),4,4′-biphenyl-bis(diphenylphosphate) and bisphenolA-bis(diphenylphosphate). These phosphate-based flame retardants may beused in combination of any two or more thereof. Among thesephosphate-based flame retardants, preferred areresorcinol-bis(dixylenylphosphate) and bisphenolA-bis(diphenylphosphate).

The content of the flame retardant in the resin composition is usually 1to 30 parts by weight, preferably 3 to 25 parts by weight and morepreferably 5 to 20 parts by weight on the basis of 100 parts by weightof a total amount of the components A, B and C. When the content of theflame retardant is less than 1 part by weight, the resultant resincomposition tend to be insufficient in flame retardancy, whereas whenthe content of the flame retardant is more than 30 parts by weight, theresultant resin composition tend to be deteriorated in heat resistance.

Examples of the dropping inhibitor used in the present invention includefluorinated polyolefins such as polyfluoroethylene. Among thesefluorinated polyolefins, especially preferred is polytetrafluoroethylenehaving a fibril-forming property which tends to be readily dispersed inthe polymer and cause molecules of the polymer to be bonded to eachother therethrough to form a fibrous material. Thepolytetrafluoroethylene having a fibril-forming property is classifiedinto Type 3 according to ASTM standard. The polytetrafluoroethylene maybe used in the form of not only a solid but also an aqueous dispersion.Examples of commercially available products of thepolytetrafluoroethylene having a fibril-forming property include “Teflon(registered trademark) 6J” and “Teflon (registered trademark) 30J” bothproduced by Mitsui-DuPont Fluorochemical Co., Ltd., and “Polyflon”(tradename) produced by Daikin Kogyo Co., Ltd.

The content of the dropping inhibitor in the resin composition isusually 0.02 to 4 parts by weight and preferably 0.03 to 3 parts byweight on the basis of 100 parts by weight of a total amount of thecomponents A, B and C. When the content of the dropping inhibitor ismore than 5 parts by weight, a molded product obtained from theresultant resin composition tend to be deteriorated in appearance.

Next, the thermoplastic resin composition according to the second aspectof the present invention is explained. The thermoplastic resincomposition according to the second aspect of the present inventioncomprises 40 to 99 parts by weight of an aromatic polycarbonate resin(component A); 1 to 60 parts by weight of a granular talc (component B)having a bulk density of 0.4 to 1.5 g/mL which is obtained bygranulating a talc having an average particle size of 0.1 to 10 μm; anda rubber polymer (component C) in an amount of 3 to 35 parts by weighton the basis of 100 parts by weight of a total amount of the componentsA and B, wherein the granular talc (component B) has a particle size inwhich a proportion of a 500 p.m-mesh screen residue thereof is not lessthan 55% by weight.

Aromatic Polycarbonate Resin (Component A):

The aromatic polycarbonate resin used as the component A in thethermoplastic resin composition according to the second aspect of thepresent invention (hereinafter occasionally referred to merely as the“component A”) is substantially the same as the aromatic polycarbonateresin (component A1) used in the thermoplastic resin compositionaccording to the first aspect of the present invention. Therefore, thedescriptions concerning the component A1 of the thermoplastic resincomposition according to the first aspect of the present invention aredirectly applied to the component A of the thermoplastic resincomposition according to the second aspect of the present invention.

Granular Talc (Component B):

The granular talc used as the component B in the thermoplastic resincomposition according to the second aspect of the present invention(hereinafter occasionally referred to merely as the “component B”) issubstantially the same as the granular talc (component B) used in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the componentB of the thermoplastic resin composition according to the first aspectof the present invention are directly applied to the component B of thethermoplastic resin composition according to the second aspect of thepresent invention.

Rubber Polymer (Component C):

The rubber polymer used as the component C in the thermoplastic resincomposition according to the second aspect of the present invention(hereinafter occasionally referred to merely as the “component C”) issubstantially the same as the rubber polymer (component C) used in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the componentC of the thermoplastic resin composition according to the first aspectof the present invention are directly applied to the component C of thethermoplastic resin composition according to the second aspect of thepresent invention.

Contents:

In the thermoplastic resin composition according to the second aspect ofthe present invention, the contents of the components A to C are asfollows. That is, the content of the aromatic polycarbonate resin(component A) is 40 to 99 parts by weight; the content of the granulartalc (component B) is 1 to 60 parts by weight; and the content of therubber polymer (component C) is 3 to 35 parts by weight on the basis of100 parts by weight of a total amount of the components A and B.

The content ratio of the component A to the component B is adjusted suchthat the content of the component A is 40 to 99 parts by weight,preferably 50 to 97 parts by weight and more preferably 60 to 95 partsby weight on the basis of 100 parts by weight of a total amount of thecomponents A and B; and the content of the component B is 1 to 60 partsby weight, preferably 3 to 50 parts by weight and more preferably 5 to40 parts by weight on the basis of 100 parts by weight of a total amountof the components A and B. When the content of the component B is lessthan 1 part by weight, the resultant resin composition tends to beinsufficient in rigidity, whereas when the content of the component B ismore than 60 parts by weight, the resultant resin composition tends tobe deteriorated in impact resistance and thermal stability.

Also, the content of the component C is 3 to 35 parts by weight,preferably 4 to 30 parts by weight and more preferably 5 to 25 parts byweight on the basis of 100 parts by weight of a total amount of thecomponents A and B. When the content of the component C is less than 3parts by weight, the resultant resin composition tends to beinsufficient in thermal stability and impact resistance. Whereas, whenthe content of the component C is more than 35 parts by weight, theresultant resin composition tends to be deteriorated in thermalstability and rigidity.

Phosphorus-based Compound (Component D):

The thermoplastic resin composition according to the second aspect ofthe present invention preferably further comprises a phosphorus-basedcompound as a component D (hereinafter occasionally referred to merelyas the “component D”) for the purpose of improving a thermal stabilityof the resin composition unless the addition of the component Dadversely affects the aimed effects of the present invention. Thephosphorus-based compound used as the component D in the thermoplasticresin composition according to the second aspect of the presentinvention is substantially the same as the phosphorus-based compound(component D) used in the thermoplastic resin composition according tothe first aspect of the present invention. Therefore, the descriptionsconcerning the component D of the thermoplastic resin compositionaccording to the first aspect of the present invention are directlyapplied to the component D of the thermoplastic resin compositionaccording to the second aspect of the present invention.

The content of the phosphorus-based compound in the rein composition ispreferably 0.001 to 1 part by weight, more preferably 0.01 to 0.8 partby weight and still more preferably 0.03 to 0.6 part by weight on thebasis of 100 parts by weight of a total amount of the components A andB.

Other Components:

The thermoplastic resin composition according to the second aspect ofthe present invention may also further comprise other resins or variousadditives for resins, if required, unless the addition of these resinsand additives adversely affects the aimed effects of the presentinvention.

The other resins are substantially the same as the thermoplastic resinother than the aromatic polycarbonate resin (component A2) used in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the componentA2 of the thermoplastic resin composition according to the first aspectof the present invention are directly applied to the other resins whichmay be used in the thermoplastic resin composition according to thesecond aspect of the present invention.

Also, the various additives for resins are substantially the same as thevarious additives for resins used as the other components in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the variousadditives for resins used in the thermoplastic resin compositionaccording to the first aspect of the present invention are directlyapplied to those used in the thermoplastic resin composition accordingto the second aspect of the present invention. Meanwhile, the amounts ofthe various additives for resins blended are as follows.

The content of the antioxidant in the resin composition is usually 0.001to 1 part by weight and preferably 0.01 to 0.5 part by weight on thebasis of 100 parts by weight of a total amount of the components A, Band C. When the content of the antioxidant is less than 0.001 part byweight, the effect of the antioxidant added tends to be insufficient.Whereas, when the content of the antioxidant is more than 1 part byweight, the effect of the antioxidant tends to be no longer increased,resulting in uneconomical process.

The content of the release agent in the resin composition is usually0.001 to 2 parts by weight and preferably 0.01 to 1 part by weight onthe basis of 100 parts by weight of a total amount of the components A,B and C. When the content of the release agent is less than 0.001 partby weight, the releasing effect tends to be insufficient, whereas whenthe content of the release agent is more than 2 parts by weight, theretend to arise problems such as deteriorated hydrolysis resistance of theresultant resin composition and contamination of a mold used uponinjection molding.

The content of the inorganic filler other than talc in the resincomposition is usually 1 to 60 parts by weight, preferably 3 to 50 partsby weight and more preferably 5 to 30 parts by weight on the basis of100 parts by weight of a total amount of the components A, B and C. Whenthe content of the inorganic filler is less than 1 part by weight, thereinforcing effect tends to be insufficient, whereas when the content ofthe inorganic filler is more than 60 parts by weight, the resultantresin composition tends to be deteriorated in appearance and impactresistance and tends to be insufficient in fluidity.

The content of the ultraviolet absorber in the resin composition isusually 0.01 to 3 parts by weight and preferably 0.1 to 1 part by weighton the basis of 100 parts by weight of a total amount of the componentsA, B and C. When the content of the ultraviolet absorber is less than0.001 part by weight, the effect of improving a weather resistance ofthe resin composition tends to be insufficient, whereas when the contentof the ultraviolet absorber is more than 3 parts by weight, there tendto arise problems such as mold deposits.

The content of the dye and pigment in the resin composition is usuallynot more than 5 parts by weight, preferably not more than 3 parts byweight and more preferably not more than 2 parts by weight on the basisof 100 parts by weight of a total amount of the components A, B and C.When the content of the dye and pigment is more than 5 parts by weight,the resultant resin composition tend to be insufficient in impactresistance.

The content of the flame retardant in the resin composition is usually 1to 30 parts by weight, preferably 3 to 25 parts by weight and morepreferably 5 to 20 parts by weight on the basis of 100 parts by weightof a total amount of the components A, B and C. When the content of theflame retardant is less than 1 part by weight, the resultant resincomposition tend to be insufficient in flame retardancy, whereas whenthe content of the flame retardant is more than 30 parts by weight, theresultant resin composition tend to be deteriorated in heat resistance.

The content of the dropping inhibitor in the resin composition isusually 0.02 to 4 parts by weight and preferably 0.03 to 3 parts byweight on the basis of 100 parts by weight of a total amount of thecomponents A, B and C. When the content of the dropping inhibitor ismore than 5 parts by weight, a molded product obtained from theresultant resin composition tend to be deteriorated in appearance.

Next, the thermoplastic resin composition according to the third aspectof the present invention is explained. The thermoplastic resincomposition according to the third aspect of the present inventioncomprises 40 to 99 parts by weight of a resin component (component A)comprising 50 to 100% by weight of an aromatic polycarbonate resin(component A1) and 50 to 0% by weight of a thermoplastic resin otherthan the aromatic polycarbonate resin (component A2) with the provisothat a total content of the components A1 and A2 is 100% by weight; 1 to60 parts by weight of a granular talc (component B) having a bulkdensity of 0.4 to 1.5 g/mL which is obtained by granulating a talchaving an average particle size of 0.1 to 10 μm; and at least one flameretardant (component E) selected from the group consisting of an organicalkali metal salt and/or an organic alkali earth metal salt (componentE1), an organophosphorus-based flame retardant (component E2) and asilicone-based resin (component E3), and a fluorinated polyolefin(component F), the components E and F being present in amounts of 0.01to 40 parts by weight and 0.01 to 5 parts by weight, respectively, onthe basis of 100 parts by weight of a total amount of the components Aand B, wherein the granular talc (component B) has a particle size inwhich a proportion of a 500 μm-mesh screen residue thereof is not lessthan 55% by weight.

Aromatic Polycarbonate Resin (Component A1):

The aromatic polycarbonate resin used as the component A1 in thethermoplastic resin composition according to the third aspect of thepresent invention (hereinafter occasionally referred to merely as the“component A1”) is substantially the same as the aromatic polycarbonateresin (component A1) used in the thermoplastic resin compositionaccording to the first aspect of the present invention. Therefore, thedescriptions concerning the component A1 of the thermoplastic resincomposition according to the first aspect of the present invention aredirectly applied to the component A1 of the thermoplastic resincomposition according to the third aspect of the present invention.

Thermoplastic Resin Other Than Aromatic Polycarbonate Resin (ComponentA2):

The thermoplastic resin other than the aromatic polycarbonate resin usedas the component A2 in the thermoplastic resin composition according tothe third aspect of the present invention (hereinafter occasionallyreferred to merely as the “component A2”) is substantially the same asthe thermoplastic resin other than the aromatic polycarbonate resin(component A2) used in the thermoplastic resin composition according tothe first aspect of the present invention. Therefore, the descriptionsconcerning the component A2 according to the first aspect of the presentinvention are directly applied to the component A2 of the thermoplasticresin composition according to the third aspect of the presentinvention.

Granular Talc (Component B):

The granular talc used as the component B in the thermoplastic resincomposition according to the third aspect of the present invention(hereinafter occasionally referred to merely as the “component B”) issubstantially the same as the granular talc (component B) used in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the componentB of the thermoplastic resin composition according to the first aspectof the present invention are directly applied to the component B of thethermoplastic resin composition according to the third aspect of thepresent invention.

Flame Retardant (Component E):

The flame retardant used as the component E in the present invention(hereinafter occasionally referred to merely as the “component E”)comprises at least one flame retardant selected from the groupconsisting of an organic alkali metal salt and/or an organic alkaliearth metal salt (component E1), an organophosphorus-based flameretardant (component E2) and a silicone-based resin (component E3).

The organic alkali metal salt and/or the organic alkali earth metal saltused as the component E1 in the present invention (hereinafteroccasionally referred to merely as the “component E1”) may be selectedfrom various known alkali and alkali earth metal salts conventionallyused for imparting a flame retardancy to aromatic polycarbonate resins.In particular, among these compounds, preferred are alkali metals saltsand/or alkali earth metal salts of organic sulfonic acids. The organicsulfonic acids used in the present invention may be selected fromvarious known ones. In particular, perfluoroalkyl sulfonic acids and/oraromatic sulfonic acids are preferred especially from the viewpoint of agood flame retardancy.

Specific examples of the perfluoroalkyl sulfonic acids includetrifluoromethane sulfonic acid, perfluorobutane sulfonic acid,perfluorohexane sulfonic acid and perfluorooctane sulfonic acid. Theseperfluoroalkyl sulfonic acids may be used alone or in combination of anytwo or more thereof. Among these perfluoroalkyl sulfonic acids,preferred are those containing a perfluoroalkyl group having 1 to 10carbon atoms, more preferred are those containing a perfluoroalkyl grouphaving 1 to 8 carbon atoms, and most preferred is perfluorobutanesulfonic acid.

Specific examples of the aromatic sulfonic acids includediphenylsulfide-4,4′-disulfonic acid, 5-sulfo-isophthalic acid,benzenesulfonic acid, dodecylbenzenesulfonic acid,naphthalene-2,6-disulfonic acid, biphenyl-3,3′-disulfonic acid,diphenylsulfone-3-sulfonic acid, diphenylsulfone-3,3′-disulfonic acid,potassium diphenylsulfoxide-4-sulfonate and naphthalenesulfonic acid.

These aromatic sulfonic acids may be used alone or in combination of anytwo or more thereof. Among these aromatic sulfonic acids, preferred arediphenylsulfide-4,4′-disulfonic acid, benzenesulfonic acid anddodecylbenzenesulfonic acid.

Examples of the alkali metal include lithium, sodium, potassium,rubidium and cesium. Examples of the alkali earth metal includeberyllium, magnesium, calcium, strontium and barium. Among these alkalimetals and alkali earth metals, preferred are lithium, sodium, potassiumand cesium.

Specific examples of the preferred organic alkali metal salt and/ororganic alkali earth metal salt include potassiumperfluorobutanesulfonate, cesium perfluorobutanesulfonate, potassiumdiphenylsulfide-4,4′-disulfonate, sodium dodecylbenzenesulfonate andpotassium dodecylbenzenesulfonate. Among these compounds, especiallypreferred is potassium perfluorobutanesulfonate.

The organophosphorus-based flame retardant used as the component E2 inthe present invention (hereinafter occasionally referred to merely asthe “component E2”) is an organic compound containing phosphorus in amolecule thereof, and may be selected from various known organiccompounds conventionally used for imparting a flame retardancy toaromatic polycarbonate resins. The organophosphorus-based flameretardant is preferably an organic phosphoric acid ester compoundrepresented by the following general formula (1) and/or general formula(2).

In the general formula (1), Fe, R² and R³ are each independently analkyl group having 1 to 6 carbon atoms or an aryl group having 6 to 20carbon atoms which may be substituted with an alkyl group; and h, i andj are each independently 0 or 1.

The organic phosphoric acid ester compound represented by the abovegeneral formula (1) may be produced from phosphorus oxychloride, etc.,by known methods. Specific examples of the phosphorus-based compoundrepresented by the general formula (1) include triphenyl phosphate,tricresyl phosphate, diphenyl 2-ethylcresyl phosphate,tri(isopropylphenyl) phosphate, diphenyl methyl phosphonate, diethylphenyl phosphonate, diphenyl cresyl phosphate and tributyl phosphate.

In the general formula (2), R⁴, R⁵, R⁶ and R⁷ are each independently analkyl group having 1 to 6 carbon atoms or an aryl group having 6 to 20carbon atoms which may be substituted with an alkyl group; p, q, r and sare each independently 0 or 1; t is an integer of 1 to 5; and X is anarylene group.

The organic phosphoric acid ester compound represented by the abovegeneral formula (2) is a condensed phosphoric acid ester in which t inthe general formula (2) is 1 to 5. When using a mixture of the condensedphosphoric acid esters which are different in the number of t from eachother, an average value of plural t's of the esters is determined as tof the mixture. In the general formula (2), X represents an arylenegroup. Examples of the arylene group include divalent groups derivedfrom dihydroxy compounds such as resorcinol, hydroquinone and bisphenolA.

Specific examples of the organic phosphoric acid ester compoundrepresented by the general formula (2), when using resorcinol as thedihydroxy compound, include phenyl-resorcin-polyphosphate,cresyl-resorcin-polyphosphate, phenyl-cresyl-resorcin-polyphosphate,xylyl-resorcin-polyphosphate,phenyl-p-t-butylphenyl-resorcin-polyphosphate,phenyl-isopropyl-phenyl-resorcin-polyphosphate,cresyl-xylyl-resorcin-polyphosphate,phenyl-isopropylphenyl-diisopropylphenyl-resorcin-polyphosphate, etc.

The organophosphorus-based flame retardant used in the present inventioninclude not only the above organic phosphoric acid ester compound, butalso a phosphazen compound. Specific examples of the phosphazen compoundinclude at least one compound selected from the group consisting ofcyclic phenoxy phosphazen compounds, chain-like phenoxy phosphazencompounds and crosslinked phenoxy phosphazen compounds.

In the present invention, among the above organophosphorus-based flameretardants, preferred are the organic phosphoric acid ester compoundsrepresented by the general formula (2), more preferred are those havingan acid value of not more than 0.5 mgKOH/g, and still more preferred arethose having an acid value of not more than 0.2 mgKOH/g. The acid valueused herein means the value measured by dissolving theorganophosphorus-based flame retardant in a mixed solvent of alcohol andether and subjecting the obtained solution to titration with 0.5Npotassium hydroxide by using phenolphthalein as an indicator.

The silicone-based resin used as the component E3 in the presentinvention (hereinafter occasionally referred to merely as the “componentE3”) may be usually selected from various optional known silicone-basedresins conventionally used for imparting a flame retardancy to aromaticpolycarbonate resins. In general, there may be used silicone-basedresins containing an aromatic hydrocarbon group and an aliphatichydrocarbon group having 2 or more carbon atoms as a substituent groupbonding to a silicon atom. Among these silicone-based resins, preferredare those silicone-based resins in which the content of the aromatichydrocarbon in the substituent group bonding to silicon atom is not lessthan 40 mol %.

Examples of the aromatic hydrocarbon group include phenyl and naphthyl.Among these groups, preferred is phenyl. The aromatic hydrocarbon groupmay have a substituent group such as an epoxy group, an amino group, ahydroxyl group and a vinyl group. Examples of the aliphatic hydrocarbongroup having 2 or more carbon atoms include unsubstituted alkyl groupssuch as ethyl, propyl, butyl, pentyl and hexyl, and substituted alkylgroups containing a substituent group such as an epoxy group, an aminogroup, a hydroxyl group and a vinyl group. The aliphatic hydrocarbongroup preferably has 2 to 12 carbon atoms.

The silicone-based resins are classified into a monofunctional totetrafunctional types depending upon the number of oxygen atoms directlybonded to silicon atom. The silicone-based resin used in the presentinvention mainly comprises a bifunctional silicone type resin (Ra₂SiO)and a trifunctional type silicone resin (RaSiO_(3/2)) and may alsocomprise a monofunctional type silicone resin (Ra₃SiO_(1/2)) or atetrafunctional type silicone resin (SiO₂). The substituent group Radirectly bonded to silicon atom is an aromatic hydrocarbon group and/oran aliphatic hydrocarbon group having 2 or more carbon atoms. In thesilicone-based resin, the content of the aromatic hydrocarbon group inthe substituent group Ra directly bonded to silicon atom is preferablynot less than 40 mol % from the viewpoint of a good flame retardancy ofthe resultant resin composition.

The silicone-based resin may be produced by various known methods. Forexample, the silicone-based resin may be produced by hydrolyzing alkyltrialkoxysilanes, aryl trialkoxysilane, dialkyl dialkoxysilanes, alkylaryl dialkoxysilanes, trialkyl alkoxysilanes, dialkyl arylalkoxysilanes, alkyl diaryl alkoxysilanes, tetraalkoxysilanes, etc. Thesilicone-based resin may be controlled in molecular structure(crosslinking degree) and molecular weight by suitably adjusting a molarratio of these raw silane compounds, hydrolysis rate, etc. Further, theraw alkoxysilanes might remain unreacted depending upon the productionconditions. If the raw alkoxysilanes remain in the resin composition,the obtained resin composition tends to be deteriorated in hydrolysisresistance. Therefore, it is preferred that the amount of residualalkoxysilanes in the resin composition is smaller or no residualalkoxysilanes are present in the resin composition.

Fluorinated Polyolefin (Component F):

Examples of the fluorinated polyolefin used as the component F in thethermoplastic resin composition according to the third aspect of thepresent invention (hereinafter occasionally referred to merely as the“component F”) include fluorinated polyolefins such aspolyfluoroethylene. Among these fluorinated polyolefins, preferred ispolytetrafluoroethylene having a fibril-forming property which tends tobe readily dispersed in the polymer and cause molecules of the polymerto be bonded to each other therethrough to form a fibrous material.

The polytetrafluoroethylene having a fibril-forming property isclassified into Type 3 according to ASTM Standard. Thepolytetrafluoroethylene may be used in the form of not only a solid butalso an aqueous dispersion. Examples of commercially available productsof the polytetrafluoroethylene having a fibril-forming property include“Teflon (registered trademark) 6J” and “Teflon (registered trademark)30J” both produced by Mitsui-DuPont Fluorochemical Co., Ltd., and“Polyflon” (tradename) produced by Daikin Kogyo Co., Ltd.

Rubber Polymer (Component C):

The thermoplastic resin composition according to the third aspect of thepresent invention preferably further comprises a rubber polymer as acomponent C (hereinafter occasionally referred to merely as the“component C”) for the purpose of improving an impact resistance of theresin composition. The component C of the thermoplastic resincomposition according to the third aspect of the present invention issubstantially the same as the rubber polymer (component C) used in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the componentC of the thermoplastic resin composition according to the first aspectof the present invention are directly applied to the component C of thethermoplastic resin composition according to the third aspect of thepresent invention.

Phosphorus-based Compound (Component D):

The thermoplastic resin composition according to the third aspect of thepresent invention preferably further comprises a phosphorus-basedcompound as a component D (hereinafter occasionally referred to merelyas the “component D”) for the purpose of improving a thermal stabilityof the resin composition unless the addition of the component Dadversely affects the aimed effects of the present invention. Thephosphorus-based compound of the thermoplastic resin compositionaccording to the third aspect of the present invention is substantiallythe same as the phosphorus-based compound (component D) used in thethermoplastic resin composition according to the first aspect of thepresent invention. Therefore, the descriptions concerning the componentD of the thermoplastic resin composition according to the first aspectof the present invention are directly applied to the component D of thethermoplastic resin composition according to the third aspect of thepresent invention.

Contents:

In the thermoplastic resin composition according to the third aspect ofthe present invention, the contents of the components A, B, E and Fconstituting the resin composition are as follows. That is, thethermoplastic resin composition comprises 40 to 99 parts by weight ofthe resin component (component A) comprising 50 to 100% by weight of thearomatic polycarbonate resin (component A1) and 50 to 0% by weight ofthe thermoplastic resin other than the aromatic polycarbonate resin(component A2) with the proviso that a total content of the componentsA1 and A2 is 100% by weight; 1 to 60 parts by weight of the granulartalc (component B); and the flame retardant (component E) and thefluorinated polyolefin (component F) in amounts of 0.01 to 40 parts byweight and 0.01 to 5 parts by weight, respectively, on the basis of 100parts by weight of a total amount of the components A and B.

In the case where the resin composition comprises the component A2, thecontent ratio of the component A1 to the component A2 is adjusted suchthat the content of the component A1 is preferably 50 to 95% by weight,more preferably 55 to 90% by weight and still more preferably 60 to 85%by weight on the basis of 100% by weight of a total amount of thecomponents A1 and A2; and the content of the component A2 is preferably50 to 5% by weight, more preferably 45 to 10% by weight and still morepreferably 40 to 15% by weight on the basis of 100% by weight of a totalamount of the components A1 and A2. When the content of the component A1is not less than 50% by weight, the resultant resin composition tends tobe enhanced in flame retardancy and impact resistance, whereas when thecontent of the component A1 is less than 95% by weight, the resultantresin composition tends to be enhanced in fluidity.

Also, the content of the component B is 1 to 60 parts by weight,preferably 3 to 50 parts by weight and more preferably 5 to 40 parts byweight on the basis of 100 parts by weight of a total amount of thecomponents A and B. When the content of the component B is less than 1part by weight, the resultant resin composition tends to be insufficientin rigidity, whereas when the content of the component B is more than 60parts by weight, the resultant resin composition tends to bedeteriorated in impact resistance and thermal stability.

As to the component E, the content of the component E1 is preferably0.02 to 1 part by weight, more preferably 0.03 to 0.5 part by weight andstill more preferably 0.05 to 0.3 part by weight on the basis of 100parts by weight of a total amount of the components A and B. When thecontent of the component E1 is not less than 0.02 part by weight, theresultant resin composition tends to be enhanced in flame retardancy,whereas when the content of the component E1 is less than 1 part byweight, the resultant resin composition tends to be enhanced in flameretardancy and thermal stability.

Also, the content of the component E2 is preferably 1 to 35 parts byweight, more preferably 3 to 30 parts by weight and still morepreferably 5 to 25 parts by weight on the basis of 100 parts by weightof a total amount of the components A and B. When the content of thecomponent E2 is not less than 1 part by weight, the resultant resincomposition tends to be enhanced in flame retardancy, whereas when thecontent of the component E2 is less than 35 parts by weight, theresultant resin composition tends to be enhanced in heat resistance andthermal stability.

In addition, the content of the component E3 is preferably 0.1 to 5parts by weight, more preferably 0.2 to 4 parts by weight and still morepreferably 0.3 to 3 parts by weight on the basis of 100 parts by weightof a total amount of the components A and B. When the content of thecomponent E3 is not less than 1 part by weight, the resultant resincomposition tends to be enhanced in flame retardancy, whereas when thecontent of the component E3 is less than 5 parts by weight, theresultant resin composition tends to be enhanced in flame retardancy andimpact resistance.

The content of the component F is 0.01 to 5 parts by weight, preferably0.05 to 3.5 parts by weight and more preferably 0.1 to 2 parts by weighton the basis of 100 parts by weight of a total amount of the componentsA and B. When the content of the component F is less than 0.01 part byweight, the resultant resin composition tends to be insufficient inflame retardancy, whereas when the content of the component F is notless than 5 parts by weight, the resultant resin composition tends to bedeteriorated in appearance of a molded product obtained from theresultant resin composition.

Next, the content of the rubber polymer (component C) is preferably 1 to30 parts by weight, more preferably 3 to 25 parts by weight and stillmore preferably 5 to 20 parts by weight on the basis of 100 parts byweight of a total amount of the components A and B. When the amount ofthe component C blended is not less than 1 part by weight, the resultantresin composition tends to be enhanced in impact resistance, whereaswhen the content of the component C is less than 30 parts by weight, theresultant resin composition tends to be enhanced in rigidity and thermalstability.

Also, the content of the phosphorus-based compound (component D) ispreferably 0.1 to 5 parts by weight, more preferably 0.3 to 4 parts byweight and still more preferably 0.5 to 3 parts by weight on the basisof 100 parts by weight of the granular talc (component B). When theamount of the component D blended is not less than 0.1 part by weight,the resultant resin composition tends to be enhanced in impactresistance, thermal stability and color tone, whereas when the contentof the component D is more than 5 parts by weight, the resultant resincomposition tends to be deteriorated in thermal stability.

Other Components:

The thermoplastic resin composition according to the third aspect of thepresent invention may also further comprise various additives forresins, if required, unless the addition of these additives adverselyaffects the aimed effects of the present invention. The variousadditives for resins are substantially the same as the various additivesfor resins used as the other components in the thermoplastic resincomposition according to the first aspect of the present invention.Therefore, the descriptions concerning the various additives for resinsof the thermoplastic resin composition according to the first aspect ofthe present invention are directly applied to those used in thethermoplastic resin composition according to the third aspect of thepresent invention. Meanwhile, the amounts of the various additives forresins blended are as follows.

The content of the antioxidant in the resin composition is usually 0.001to 1 part by weight and preferably 0.01 to 0.5 part by weight on thebasis of 100 parts by weight of a total amount of the components A andB. When the content of the antioxidant is less than 0.001 part byweight, the effect of the antioxidant added tends to be insufficient.Whereas, when the content of the antioxidant is more than 1 part byweight, the effect of the antioxidant tends to be no longer increased,resulting in uneconomical process.

The content of the release agent in the resin composition is usually0.001 to 2 parts by weight and preferably 0.01 to 1 part by weight onthe basis of 100 parts by weight of a total amount of the components Aand B. When the content of the release agent is less than 0.001 part byweight, the releasing effect tends to be insufficient, whereas when thecontent of the release agent is more than 2 parts by weight, there tendto arise problems such as deteriorated hydrolysis resistance of theresultant resin composition and contamination of a mold used uponinjection molding.

The content of the ultraviolet absorber in the resin composition isusually 0.01 to 3 parts by weight and preferably 0.1 to 1 part by weighton the basis of 100 parts by weight of a total amount of the componentsA and B. When the content of the ultraviolet absorber is less than 0.001part by weight, the effect of improving a weather resistance of theresin composition tends to be insufficient, whereas when the content ofthe ultraviolet absorber is more than 3 parts by weight, there tend toarise problems such as mold deposits.

The content of the dye and pigment in the resin composition is usuallynot more than 5 parts by weight, preferably not more than 3 parts byweight and more preferably not more than 2 parts by weight on the basisof 100 parts by weight of a total amount of the components A and B. Whenthe content of the dye and pigment is more than 5 parts by weight, theresultant resin composition tend to be insufficient in impactresistance.

The content of the inorganic filler other than talc in the resincomposition is usually 1 to 60 parts by weight, preferably 3 to 50 partsby weight and more preferably 5 to 30 parts by weight on the basis of100 parts by weight of a total amount of the components A and B. Whenthe content of the inorganic filler is less than 1 part by weight, thereinforcing effect tends to be insufficient, whereas when the content ofthe inorganic filler is more than 60 parts by weight, the resultantresin composition tends to be deteriorated in appearance and impactresistance and tends to be insufficient in fluidity.

Next, the processes for producing the thermoplastic resin compositionsaccording to the first to third aspects of the present invention areexplained. The thermoplastic resin compositions of the present inventionshould not be particularly limited only to specific ones as long as theycomprise the essential components for the respective thermoplastic resincompositions according to the first to third aspects of the presentinvention, in the amounts as specified above. Therefore, the processesfor production of these thermoplastic resin compositions may also beappropriately selected depending upon the respective compositions. Forexample, the thermoplastic resin compositions of the present inventionmay be produced by extensive known methods conventionally used forproducing thermoplastic resin compositions.

More specifically, the respective thermoplastic resin compositions ofthe present invention may be produced by previously mixing the aboveessential components and, if required, optional components, with eachother using various mixers such as a tumbler and a Henschel mixer, andthen melt-kneading the resultant mixture using a Banbury mixer, a roll,a Brabender, a single-screw kneading extruder, a twin-screw kneadingextruder, a kneader, etc.

Alternatively, the respective components may be directly fed withoutbeing previously mixed, or may be fed after previously mixing only apart of the components, to the extruder through a feeder, and thenmelt-kneaded, thereby producing the resin composition. This methodallows the component B to be fed without being previously mixed with theother components to the extruder through the feeder and melt-kneadedtherewith in the extruder to produce the resin composition. Therefore,such a method is preferred from the viewpoint of extrusion moldingworkability because deterioration in working environmental conditionsdue to occurrence of scattering or dusting of the granular talc can beavoided. Further, upon production of the thermoplastic resin compositionaccording to the third aspect of the present invention, when thecomponent is kept in a liquid state at an ordinary temperature, from theviewpoint of a good flame retardancy of the resultant resin composition,there may be suitably used such a method in which the components otherthan the component E are fed into the extruder at one time on anupstream side thereof, and thereafter the component E is fed subsequentto the midstream thereof and then melt-kneaded together with the resincomponents fed previously.

Production of Resin Molded Product:

The process for producing a resin molded product from the respectivethermoplastic resin compositions according to the first to third aspectsof the present invention is not particularly limited. The resin moldedproduct may be produced by various methods ordinarily used for moldingthermoplastic resins such as an injection molding method, anultrahigh-speed injection molding method, an injection compressionmolding method, a two-color molding method, a gas-assisted blow moldingmethod, a molding method using an insulated runner mold, a moldingmethod using a rapidly heating mold, an expansion molding method(including supercritical fluid), an insert molding method, an IMC(in-mold coating molding) method, an extrusion molding method, a sheetmolding method, a thermoforming method, a rotational molding method, alamination molding method and a press molding method. In addition, theremay also be adopted such a molding method using a hot runner.

Further, in the present invention, from the viewpoints of less amount ofwastes, reduction in environmental burden and low costs, upon producingthe resin molded product from the resin composition, the virgin materialmay be mixed with recycled raw materials such as nonconforming products,sprues, runners and used products in order to realize recycling ofmaterials (so-called material-recycling). In this case, the recycled rawmaterials used are preferably crushed or pulverized to preventoccurrence of defects upon producing the molded product. The content ofthe recycled raw materials is usually not more than 70% by weight,preferably not more than 50% by weight and more preferably not more than30% by weight based on a total amount of the recycled raw materials andthe virgin material.

EXAMPLES

The present invention is described in more detail by the followingExamples. However, these Examples are only illustrative and not intendedto limit a scope of the present invention. Meanwhile, in the followingexamples and comparative examples, Examples 1-1 to 1-16 and ComparativeExamples 1-1 to 1-14 correspond to the thermoplastic resin compositionaccording to the first aspect of the present invention; Examples 2-1 to2-9 and Comparative Examples 2-1 to 2-5 correspond to the thermoplasticresin composition according to the second aspect of the presentinvention; and Examples 3-1 to 3-9 and Comparative Examples 3-1 to 3-9correspond to the thermoplastic resin composition according to the thirdaspect of the present invention. In addition, in the following examplesand comparative examples, the amounts of the respective componentsblended mean “part(s) by weight”.

The following raw materials were prepared upon producing the respectiveresin compositions in Examples and Comparative Examples.

<Aromatic Polycarbonate Resin>

Aromatic polycarbonate resin (1): Bisphenol A-type aromaticpolycarbonate produced by interfacial polymerization method (“IUPILONS-3000FN” produced by Mitsubishi Engineering-Plastics Corporation;viscosity-average molecular weight: 22,500; end hydroxyl groupconcentration: 150 ppm)

Aromatic polycarbonate resin (2): Bisphenol A-type aromaticpolycarbonate produced by interfacial polymerization method (“IUPILONH-4000FN” produced by Mitsubishi Engineering-Plastics Corporation;viscosity-average molecular weight: 15,500; end hydroxyl groupconcentration: 150 ppm)

Aromatic polycarbonate resin (3): Bisphenol A-type aromaticpolycarbonate produced by interfacial polymerization method (“IUPILONE-2000FN” produced by Mitsubishi Engineering-Plastics Corporation;viscosity-average molecular weight: 28,000; end hydroxyl groupconcentration: 150 ppm)

<Thermoplastic Resin Other than Aromatic Polycarbonate Resin>

Polyethylene terephthalate resin; “NOVAPEX GG500” produced by MitsubishiChemical Corporation; intrinsic viscosity: 0.76 dL/g

Polybutylene terephthalate resin (1); “NOVADURAN 5020” produced byMitsubishi Engineering-Plastics Corporation; intrinsic viscosity: 1.20dL/g

Polybutylene terephthalate resin (2); “NOVADURAN 5008” produced byMitsubishi Engineering-Plastics Corporation; intrinsic viscosity: 0.85dL/g

ABS resin (1): acrylonitrile-butadiene-styrene copolymer; “SUNTAC AT-08”produced by Nippon A & L Co., Ltd.; butadiene rubber content: 18% byweight

ABS resin (2): acrylonitrile-butadiene-styrene copolymer; “DP-611”produced by Techno-Polymer Co., Ltd.; butadiene rubber content: 40% byweight

<Granular Talc>

Granular talc (1): “MTB-12” produced by Matsumura Sangyo Co., Ltd.;average particle size of talc: 1.8 p.m; bulk density: 0.74 g/mL;particle size/500 μm-mesh screen residue: 98% by weight; particle shape:cylindrical; average axis diameter: 1.2 mm; average axis length: 1.5 mm;kind of binder: CMC (“CELOGEN 7A” produced by Dai-Ichi Kogyo SeiyakuCo., Ltd.); content of binder: 0.3% by weight; lubricant: water; watercontent: 0.11%

Granular talc (2): “MTB-11” produced by Matsumura Sangyo Co., Ltd.;average particle size of talc: 1.8 μm; bulk density: 0.72 g/mL; particlesize/500 μm-mesh screen residue: 97% by weight; particle shape:cylindrical; average axis diameter: 1.2 mm; average axis length: 1.5 mm;kind of binder: second-class glue (JIS K₆₅₀₃, “AGX-5195B” produced byNitta Gelatin Co., Ltd.); content of binder: 0.5% by weight; lubricant:water; water content: 0.12%

Granular talc (3): “MTB-5” produced by Matsumurasangyo Co., Ltd.;average particle size of talc: 1.8 μm; bulk density: 0.69 g/mL; particlesize/500 μm-mesh screen residue: 92% by weight; particle shape:cylindrical; average axis diameter: 1.2 mm; average axis length: 1.5 mm;kind of binder: bentonite; content of binder: 0.5% by weight; lubricant:water; water content: 0.15%

Granular Talc (4):

A 20-L Henschel mixer was charged with 4992.5 g of talc (“HIGH-FILLER#5000PJ” produced by Matsumurasangyo Co., Ltd.) having an averageparticle size of 1.8 μm, and then an aqueous solution previouslyprepared by dissolving 7.5 g of CMC (“CELOGEN 7A” produced by Dai-IchiKogyo Seiyaku Co., Ltd.) in 2000 g of clean water was added thereto over2 min while stirring the talc at a high speed by operating an agitationblade at 1500 rpm. After adding the aqueous solution, the resultantmixture was further continuously stirred for 3 min, thereby obtaining aclay-like kneaded material.

Next, the thus obtained kneaded material was extruded and granulatedusing a roll-basket type granulating apparatus equipped with a 1.2μm-mesh screen, and then dried using a fluidized bed dryer at a hot airtemperature of 100° C. for about 60 min, thereby obtaining a granulartalc. Further, the particle size of the granular talc was uniformedusing a granulator, thereby obtaining cylindrical granules having anaverage axis diameter of 1.2 mm and an average axis length of 1.5 mm(hereinafter referred to merely as the “granular talc (4)”). As aresult, it was confirmed that the thus obtained granular talc had a bulkdensity of 0.68 g/mL, a particle size/500 μm-mesh screen residue of 68%by weight and a water content of 0.3%.

<Comparative Talc>

Powdery talc: “HIGH-FILLER #5000PJ” produced by Matsumurasangyo Co.,Ltd.; average particle size: 1.8 μm; bulk density: 0.12 g/mL; particlesize/500 μm-mesh screen residue: 0% by weight

Compressed talc: “UPN HS-T0.8” produced by Hayashi Kasei Co., Ltd.;degassed compressed product; average particle size: 2 μm; bulk density:0.8 g/mL; particle size/500 μm-mesh screen residue: 32% by weight

Granular talc (5): “HiTalc HTP ultra5C” produced by IMI-FABI Corp.;average particle size: 0.5 μm; bulk density: 0.9 g/mL; particle size/500μm-mesh screen residue: 48% by weight

<Rubber Polymer>

Rubber polymer (1): Core/shell type graft copolymer comprisingpoly(alkyl acrylate) (core)/alkyl acrylate-alkyl methacrylate copolymer(shell); “EXL2315” produced by Rohm & Haas Japan Co., Ltd.

Rubber polymer (2): Core/shell type graft copolymer comprisingpolybutadiene (core)/alkyl acrylate-alkyl methacrylate copolymer(shell); “EXL2603” produced by Rohm & Haas Japan Co., Ltd.

<Flame Retardant>

Organic alkali metal salt: Potassium perfluorobutanesulfonate; “KFBS”produced by Mitsubishi Materials Corporation.

Organophosphorus-based flame retardant: Organic condensed phosphatecompound (in the general formula (2), X=1,3-phenylene, R⁴ toR⁷=2,6-xylyl, acid value: 0.12 mgKOH/g); “ADK STAB FP-500” produced byADEKA Corporation.

Silicone-based resin: Organosiloxane polymer containing a propyl groupand a phenyl group as a substituent group bonded to silicon atom whichwas kept in a solid state at an ordinary temperature; “SH6018” producedby Toray Dow Corning Co., Ltd.

<Fluorinated Polyolefin>

Fluorinated polyolefin: Polytetrafluoroethylene; “POLYFLON F-201L”produced by Daikin Kogyo Co., Ltd.

<Phosphorus-based Compound>

Phosphorus-based compound (1): Chemical formula:O═P(OH)_(n′)(C₁₈H₃₇)_(3-n′) (mixture of the compound wherein n′=1 andthe compound wherein n′=2); “ADK STAB AX-71” produced by ADEKACorporation.

Phosphorus-based compound (2):Bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite; “ADK STABPEP-24G” produced by ADEKA Corporation.

<Other Components>

Carbon black: Oil furnace carbon black; “#1000” produced by MitsubishiChemical Corporation.

Titanium oxide: Titanium dioxide surface-treated with methyl hydrogenpolysiloxane; “TIEPAKE PC-3” produced by Ishihara Sangyo Co., Ltd.

Antioxidant: Pentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]; “IRGANOX1010” produced by Ciba Specialty Chemicals Corp.

Release agent: Pentaerythritol tetrastearate; “UNISTAR H476” produced byNippon Oils & Fats Co., Ltd.

<Evaluation Methods>

The evaluation methods used in the following examples and comparativeexamples are shown below. Meanwhile, the methods for producing therespective test specimens are described in the following examples.

(1) Fluidity (Q Value):

Using a high load-type flow tester, the amount of the resin compositiondischarged per unit time (Q value; unit: cc/sec) was measured at 280° C.under a load of 160 kgf/cm² to evaluate a fluidity thereof. Meanwhile,an orifice used had a diameter of 1 mm and a length of 10 mm.

(2) Rigidity (Bending Modulus)

According to ASTM D790, a test specimen having a thickness of 6.4 mm wastested to measure a bending modulus thereof (unit: MPa) at 23° C.

(3) Impact Resistance: a: Izod Impact Strength:

According to ASTM D256, a notched test specimen having a thickness of3.2 mm was tested to measure an Izod impact strength thereof (unit: J/m)at 23° C.

b: Tensile Breaking Elongation:

According to ASTM D638, a test specimen having a thickness of 3.2 mm wassubjected to tensile test (pulling speed: 10 mm/min) at 23° C. tomeasure a tensile breaking elongation thereof (unit: %).

c: Surface Impact Strength:

The above disc-shaped molded product (ordinary molded product) wassubjected to impact test in which the molded product was punched at apunch diameter of ½ inch, a support diameter of 3 inch and a punchingspeed of 1 m/s using a high-rate impact tester (manufactured by ShimadzuSeisakusho Co., Ltd.). The larger the surface impact strength (breakingenergy; unit: J), the more excellent the impact resistance.

(4) Retention Thermal Stability: a: Surface Appearance:

The surface appearance of the above disc-shaped molded product(retention molded product) was observed by naked eyes, and evaluated asfollows.

⊚: No surface roughening due to silver streak.

◯: Almost no surface roughening due to silver streak.

X: Severe surface roughening due to silver streak.

b: Surface Impact Strength:

The above disc-shaped molded product (retention molded product) wassubjected to impact test in which the molded product was punched at apunch diameter of ½ inch, a support diameter of 3 inch and a punchingspeed of 1 m/s using a high-rate impact tester (manufactured by ShimadzuSeisakusho Co., Ltd.). The larger the surface impact strength (breakingenergy; unit: J), the more excellent the impact resistance.

(5) Extrusion Moldability

The extrusion moldability upon producing the resin composition wasevaluated according to the following ratings.

◯: Strands and pellets were readily produced with an extrusion output ofnot less than 40 k/h without problems such as clogging of a hopper anddefective intrusion into an extruder.

X: Problems such as clogging of a hopper and defective intrusion into anextruder occurred, and strands and pellets were not produced unlessreducing an extrusion output.

(6) Flame Retardancy (UL94 Standard Vertical Combustion Test):

The above-prepared combustion test specimens respectively having athickness of 1.6 mm and 1.2 mm were subjected to vertical combustiontest according to UL94 Standard to evaluate a combustibility thereof.

Examples 1-1 to 1-16 and Comparative Examples 1-1 to 1-14 ThermoplasticResin Compositions According to the First Aspect of the PresentInvention <Production of Resin Composition> Examples 1-1 to 1-15 andComparative Examples 1-1 to 1-11

The respective components as shown in Tables 1 to 4 were uniformly mixedat the proportions shown in the same Tables with each other using atumbler mixer. Then, the resultant mixture was fed to a twin-screwextruder “TEX30XCT” (L/D=42; number of barrels: 12) manufactured byNippon Seikosho Co., Ltd., through a barrel 1 thereof, melt-kneadedtherein at a cylinder temperature of 270° C. and a screw rotating speedof 250 rpm, and extruded therefrom, thereby obtaining a resincomposition in the form of pellets.

Example 1-16 and Comparative Examples 1-12 to 1-14

The respective components as shown in Table 5 were uniformly mixed atthe proportions shown in the same Table with each other using a tumblermixer. Then, the resultant mixture was fed to a twin-screw extruder“TEX30XCT” (L/D=42; number of barrels: 12) manufactured by NipponSeikosho Co., Ltd., through a barrel 1 thereof, melt-kneaded therein ata cylinder temperature of 250° C. and a screw rotating speed of 250 rpm,and extruded therefrom, thereby obtaining a resin composition in theform of pellets.

<Production of Test Specimen> Examples 1-1 to 1-3 and ComparativeExamples 1-1 to 1-5

The pellets obtained from the above-produced resin composition weredried at 110° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 280° C., a mold temperature of 80° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Also, retention molding was carried out at a molding cycle timeof 2.5 min per each cycle, and the disc-shaped retention molded productssubsequent to the 5th shot were respectively subjected to evaluation ofproperties thereof.

Examples 1-4 to 1-15 and Comparative Examples 1-6 to 1-11

The pellets obtained from the above-produced resin composition weredried at 110° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 280° C., a mold temperature of 80° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Also, retention molding was carried out at a molding cycle timeof 5 min per each cycle, and the disc-shaped retention molded productssubsequent to the 5th shot were respectively subjected to evaluation ofproperties thereof.

Example 1-16 and Comparative Examples 1-12 to 1-14

The pellets obtained from the above-produced resin composition weredried at 120° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 260° C., a mold temperature of 80° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Also, retention molding was carried out at a molding cycle timeof 5 min per each cycle, and the disc-shaped retention molded productssubsequent to the 5th shot were respectively subjected to evaluation ofproperties thereof.

Examples 1-1 to 1-16 and Comparative Examples 1-1 to 1-14

The respective resin compositions shown in Tables 1 to 5 were producedand evaluated by the above-mentioned methods. The results are shown inTables 1 to 5.

TABLE 1 Examples Comparative Examples 1-1 1-2 1-3 1-1 1-2 1-3 1-4 1-5Composition (wt. part) Aromatic 63 63 63 90 85.5 63 63 63 polycarbonateresin (1) Polyethylene 27 27 27 — 4.5 27 27 27 terephthalate resinGranular talc (1) 10 — — 10 10 — — — Granular talc (2) — 10 — — — — — —Granular talc (3) — — 10 — — — — — Powdery talc — — — — — 10 — —Compressed talc — — — — — — 10 — Granular talc (5) — — — — — — — 10Carbon black 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 Evaluation resultsFluidity: Q value 19 19 25 55 50 59 53 51 (×10⁻² cc/s) Rigidity: Bending3650 3600 3630 3300 3340 3580 3590 3590 modulus (MPa) Impact resistance:Izod impact 50 45 40 28 30 25 27 28 strength (J/m) Tensile breaking 110100 80 9 11 8 9 10 elongation (%) Surface impact 80 72 65 13 16 15 18 20strength (J) Retention thermal ◯ ◯ ◯ X X X X X stability: Surfaceappearance: visually observed Extrusion ◯ ◯ ◯ ◯ ◯ X X X moldability

TABLE 2 Comparative Examples Examples 1-4 1-5 1-6 1-7 1-8 Composition(wt. part) Aromatic polycarbonate 19.6 19.6 19.6 19.6 19.6 resin (1)Aromatic polycarbonate 29.4 29.4 29.4 29.4 29.4 resin (2) Polyethylene21 21 21 21 21 terephthalate resin Granular talc (1) 20 — — — — Granulartalc (4) — 20 — — — Powdery talc — — 20 — — Compressed talc — — — 20 —Granular talc (5) — — — — 20 Rubber polymer (1) 10 10 10 10 10Phosphorus-based 0.2 0.2 0.2 0.2 0.2 compound Carbon black 0.01 0.010.01 0.01 0.01 Titanium oxide 0.3 0.3 0.3 0.3 0.3 Evaluation resultsFluidity: Q value 34 39 90 88 80 (×10⁻² cc/s) Rigidity: Bending 41003980 3800 3830 3970 modulus (MPa) Impact resistance: Izod impactstrength 55 45 28 29 29 (J/m) Impact strength (J) 53 36 2 3 3 Retentionthermal stability: Surface appearance: ⊚ ◯ X X X visually observedImpact strength (J) 45 18 1 1 1 Extrusion moldability ◯ ◯ X X X

TABLE 3 Examples 1-6 1-7 1-8 1-9 1-10 1-11 Composition (wt. part)Aromatic polycarbonate 49 22 22.4 56 20 — resin (1) Aromaticpolycarbonate — — 33.6 — 30 — resin (2) Aromatic polycarbonate — 20 — —— 62 resin (3) Polyethylene terephthalate 21 18 24 24 30 27 resinGranular talc (1) 20 30 10 10 10 6 Rubber polymer (1) 10 10 10 — 10 5Rubber polymer (2) — — — 10 — — Phosphorus-based compound 0.2 0.3 0.30.1 0.1 0.05 Carbon black 0.01 0.01 0.01 0.01 0.01 0.01 Titanium oxide0.3 0.3 0.3 0.3 0.3 0.3 Evaluation results Fluidity: Q value 17 14 33 1837 8 (×10⁻² cc/s) Rigidity: Bending modulus 4080 5450 2940 2950 30502650 (MPa) Impact resistance: Izod impact strength (J/m) 92 60 97 360 83700 Impact strength (J) 62 35 66 75 58 76 Retention thermal stability:Surface appearance: ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ visually observed Impact strength (J) 5318 59 52 48 62 Extrusion moldability ◯ ◯ ◯ ◯ ◯ ◯

TABLE 4 Comparative Examples Examples 1-12 1-13 1-14 1-15 1-9 1-10 1-11Composition (wt. part) Aromatic polycarbonate 22.4 22.4 19.6 — 22.4 22.422.4 resin (1) Aromatic polycarbonate 33.6 33.6 29.4 — 33.6 33.6 33.6resin (2) Aromatic polycarbonate — — — 52 — — — resin (3) Polybutylene24 19 17 22 24 24 24 terephthalate resin (1) Polyethylene — 5 4 6 — — —terephthalate resin Granular talc (1) 10 10 20 10 — — — Powdery talc — —— 10 — — Compressed talc — — — 10 — Granular talc (5) — — — — 10 Rubberpolymer (1) 10 10 10 — 10 10 10 Rubber polymer (2) — — — 10 — — —Phosphorus-based 0.1 0.1 0.2 0.1 0.1 0.1 0.1 compound Carbon black 0.010.01 0.01 0.01 0.01 0.01 0.01 Titanium oxide 0.3 0.3 0.3 0.3 0.3 0.3 0.3Evaluation results Fluidity: Q value 24 22 20 9.2 40 37 36 (×10⁻² cc/s)Rigidity: Bending 2840 2880 3950 3000 2760 2770 2820 modulus (MPa)Impact resistance: Izod impact strength 130 128 85 600 90 95 96 (J/m)Impact strength (J) 69 68 50 76 57 59 59 Retention thermal stability:Surface appearance: ◯ ⊚ ◯ ⊚ X X X visually observed Impact strength (J)51 56 38 55 14 18 15 Extrusion moldability ◯ ◯ ◯ ◯ X X X

TABLE 5 Example Comparative Examples 1-16 1-12 1-13 1-14 Composition(wt. part) Aromatic polycarbonate resin 8 8 8 8 (1) Aromaticpolycarbonate resin 13 13 13 13 (2) Polybutylene terephthalate 34 34 3434 resin (1) Polybutylene terephthalate 15 15 15 15 resin (2) Granulartalc (1) 20 — — — Powdery talc — 20 — — Compressed talc — — 20 —Granular talc (5) — — — 20 Rubber polymer (1) 10 10 10 10Phosphorus-based compound 0.2 0.2 0.2 0.2 Carbon black 0.3 0.3 0.3 0.3Evaluation results Fluidity: Q value (×10⁻² cc/s) 40 56 54 53 Rigidity:Bending modulus 4100 3880 3930 4030 (MPa) Impact resistance: Izod impactstrength (J/m) 46 35 36 36 Impact strength (J) 48 36 38 37 Retentionthermal stability: Surface appearance: visually ◯ X X X observed Impactstrength (J) 32 1 1 1 Extrusion moldability ◯ X X X

From the results of Examples and Comparative Examples shown in Tables 1to 5, the followings were confirmed. The resin compositions obtained inExamples 1-1 to 1-3 according to the present invention were excellent inthermal stability, impact resistance and rigidity. On the other hand,the resin composition obtained in Comparative Example 1-1 whichcontained no component A2 and the resin composition obtained inComparative Example 1-2 in which the content of the component A2 was outof the specific range defined by the present invention were deterioratedin thermal stability and impact resistance, and the resin compositionsobtained in Comparative Examples 1-3 to 1-5 in which the content of thecomponent B was out of the specific range defined by the presentinvention were also deteriorated in thermal stability and impactresistance.

The resin compositions obtained in Examples 1-4 to 1-11 were excellentin thermal stability, impact resistance and rigidity. On the other hand,the resin compositions obtained in Comparative Examples 1-6 to 1-8 inwhich the content of the component B was out of the specific rangedefined by the present invention were deteriorated in thermal stabilityand impact resistance.

The resin compositions obtained in Examples 1-12 to 1-15 were excellentin thermal stability, impact resistance and rigidity. On the other hand,the resin compositions obtained in Comparative Examples 1-9 to 1-11 inwhich the content of the component B was out of the specific rangedefined by the present invention were deteriorated in thermal stabilityand impact resistance.

The resin composition obtained in Example 1-16 was excellent in thermalstability, impact resistance and rigidity. On the other hand, the resincompositions obtained in Comparative Examples 1-12 to 1-14 in which thecontent of the component B was out of the specific range defined by thepresent invention were deteriorated in thermal stability and impactresistance.

Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-5 ThermoplasticResin Compositions According to the Second Aspect of the PresentInvention <Production of Resin Composition>

The respective components as shown in Tables 6 and 7 were uniformlymixed at the proportions shown in the same Tables with each other usinga tumbler mixer. Then, the resultant mixture was fed to a twin-screwextruder “TEX30XCT” (L/D=42; number of barrels: 12) manufactured byNippon Seikosho Co., Ltd., through a barrel 1 thereof, melt-kneadedtherein at a cylinder temperature of 270° C. and a screw rotating speedof 250 rpm, and extruded therefrom, thereby obtaining a resincomposition in the form of pellets.

<Production of Test Specimen>

The pellets obtained from the above-produced resin composition weredried at 120° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 280° C., a mold temperature of 80° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Also, retention molding was carried out at a molding cycle timeof 4 min per each cycle, and the disc-shaped retention molded productssubsequent to the 5th shot were respectively subjected to evaluation ofproperties thereof.

Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-5

The respective resin compositions shown in Tables 6 and 7 were producedand evaluated by the above-mentioned methods. The results are shown inTables 6 and 7.

TABLE 6 Examples 2-1 2-2 2-3 2-4 Composition (wt. part) Aromaticpolycarbonate 36 36 36 36 resin (1) Aromatic polycarbonate 54 54 54 54resin (2) Granular talc (1) 10 — — — Granular talc (2) — 10 — — Granulartalc (3) — — 10 — Granular talc (4) — — — 10 Powdery talc — — — —Compressed talc — — — — Granular talc (5) — — — — Rubber polymer (1) 1010 10 10 Phosphorus-based 0.1 0.1 0.1 0.1 compound (1) Carbon black 0.30.3 0.3 0.3 Evaluation results Fluidity: Q value 19 19 20 21 (×10⁻²cc/s) Rigidity: Bending 2840 2800 2790 2790 modulus (MPa) Impactresistance: Izod 240 210 205 215 impact strength (J/m) Retention thermal⊚ ◯ ◯ ◯ stability: Surface appearance: visually observed Extrusionmoldability ◯ ◯ ◯ ◯ Comparative Examples 2-1 2-2 2-3 2-4 2-5 Composition(wt. part) Aromatic polycarbonate 36 36 36 36 36 resin (1) Aromaticpolycarbonate 54 54 54 54 54 resin (2) Granular talc (1) 10 10 — — —Granular talc (2) — — — — — Granular talc (3) — — — — — Granular talc(4) — — — — — Powdery talc — — 10 — — Compressed talc — — — 10 —Granular talc (5) — — — — 10 Rubber polymer (1) — 2 10 10 10Phosphorus-based 0.1 0.1 0.1 0.1 0.1 compound (1) Carbon black 0.3 0.30.3 0.3 0.3 Evaluation results Fluidity: Q value 30 28 22 20 20 (×10⁻²cc/s) Rigidity: Bending 3250 3150 2700 2730 2800 modulus (MPa) Impactresistance: Izod 45 55 130 140 130 impact strength (J/m) Retentionthermal X X X X X stability: Surface appearance: visually observedExtrusion moldability ◯ ◯ X X X

TABLE 7 Examples 2-5 2-6 2-7 2-8 2-9 Composition (wt. part) Aromaticpolycarbonate 36 36 34 90 61 resin (1) Aromatic polycarbonate 54 54 51 —— resin (2) Aromatic polycarbonate — — — — 33 resin (3) Granular talc(1) 10 10 15 10 6 Rubber polymer (1) 10 — 10 — — Rubber polymer (2) — 10— 6 6 Phosphorus-based — 0.1 0.2 0.1 0.1 compound (1) Phosphorus-based0.3 — — — — compound (2) Carbon black 0.3 0.3 0.3 0.3 0.3 Evaluationresults Fluidity: Q value 18 16 18 8 5 (×10⁻² cc/s) Rigidity: Bending2840 2780 3300 3030 2650 modulus (MPa) Impact resistance: Izod 235 280125 330 680 impact strength (J/m) Retention thermal stability: Surfaceappearance: ⊚ ⊚ ⊚ ⊚ ⊚ visually observed Extrusion moldability ◯ ◯ ◯ ◯ ◯

From the results of Examples and Comparative Examples shown in Tables 6and 7, the followings were confirmed. The resin compositions obtained inExamples 2-1 to 2-9 according to the present invention were excellent inthermal stability, impact resistance and rigidity. On the other hand,the resin composition obtained in Comparative Example 2-1 whichcontained no component C and the resin composition obtained inComparative Example 2-2 in which the content of the component C was outof the specific range defined by the present invention were deterioratedin thermal stability and impact resistance, and the resin compositionsobtained in Comparative Examples 2-3 to 2-5 in which the content of thecomponent B was out of the specific range defined by the presentinvention were also deteriorated in thermal stability and impactresistance.

Examples 3-1 to 3-9 and Comparative Examples 3-1 to 3-9 ThermoplasticResin Compositions According to the Third Aspect of the PresentInvention <Production of Resin Composition and Production of TestSpecimen> Examples 3-1 to 3-4 and Comparative Examples 3-1 to 3-3

The respective components as shown in Table 8 were uniformly mixed atthe proportions shown in the same Table with each other using a tumblermixer. Then, the resultant mixture was fed to a twin-screw extruder“TEX30XCT” (L/D=42; number of barrels: 12) manufactured by NipponSeikosho Co., Ltd., through a barrel 1 thereof, melt-kneaded therein ata cylinder temperature of 270° C. and a screw rotating speed of 300 rpm,and extruded therefrom, thereby obtaining a resin composition in theform of pellets.

The pellets obtained from the above-produced resin composition weredried at 120° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 280° C., a mold temperature of 80° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Also, using an injection molding machine “J50 Model”manufactured by Nippon Seikosho Co., Ltd., a UL94 Standard verticalcombustion test specimen having a size of 127 mm in length×12.7 mm inwidth×1.6 mm or 1.2 mm in thickness was produced at a cylindertemperature of 280° C., a mold temperature of 80° C. and a molding cycletime of 50 sec.

Examples 3-5 to 3-7 and Comparative Examples 3-4 to 3-6

The respective components as shown in Table 9 were uniformly mixed atthe proportions shown in the same Table with each other using a tumblermixer. Then, the resultant mixture was fed to a twin-screw extruder“TEX30XCT” (L/D=42; number of barrels: 12) manufactured by NipponSeikosho Co., Ltd., through a barrel 1 thereof, melt-kneaded therein ata cylinder temperature of 260° C. and a screw rotating speed of 300 rpm,and extruded therefrom, thereby obtaining a resin composition in theform of pellets.

The pellets obtained from the above-produced resin composition weredried at 100° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 270° C., a mold temperature of 80° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Further, retention molding was carried out at a molding cycletime of 5 min per each cycle, and the disc-shaped retention moldedproducts subsequent to the 5th shot were respectively subjected toevaluation of properties thereof. Also, using an injection moldingmachine “J50 Model” manufactured by Nippon Seikosho Co., Ltd., a UL94Standard vertical combustion test specimen having a size of 127 mm inlength×12.7 mm in width×1.2 mm in thickness was produced at a cylindertemperature of 270° C., a mold temperature of 80° C. and a molding cycletime of 50 sec.

Examples 3-8 and 3-9 and Comparative Examples 3-7 to 3-9

The respective components as shown in Table 10 were uniformly mixed atthe proportions shown in the same Table with each other using a tumblermixer. Then, the resultant mixture was fed to a twin-screw extruder“TEX30XCT” (L/D=42; number of barrels: 12) manufactured by NipponSeikosho Co., Ltd., through a barrel 1 thereof, melt-kneaded therein ata cylinder temperature of 250° C. and a screw rotating speed of 300 rpm,and extruded therefrom, thereby obtaining a resin composition in theform of pellets.

The pellets obtained from the above-produced resin composition weredried at 80° C. for 6 hr or longer, and then molded using an injectionmolding machine “M150AII-SJ Model” manufactured by Meiki Seisakusho Co.,Ltd., at a cylinder temperature of 250° C., a mold temperature of 60° C.and a molding cycle time of 55 sec, thereby producing an ASTM testspecimen and a 100 mmφ disc-shaped molded product (having a thickness of3 mmt). Further, retention molding was carried out at a molding cycletime of 5 min per each cycle, and the disc-shaped retention moldedproducts subsequent to the 5th shot were respectively subjected toevaluation of properties thereof. Also, using an injection moldingmachine “J50 Model” manufactured by Nippon Seikosho Co., Ltd., a UL94Standard vertical combustion test specimen having a size of 127 mm inlength×12.7 mm in width×1.2 mm in thickness was produced at a cylindertemperature of 250° C., a mold temperature of 60° C. and a molding cycletime of 50 sec.

Examples 3-1 to 3-9 and Comparative Examples 3-1 to 3-9

The respective resin compositions shown in Tables 8 to 10 were producedand evaluated by the above-mentioned methods. The results are shown inTables 8 to 10.

TABLE 8 Comparative Examples Examples 3-1 3-2 3-3 3-4 3-1 3-2 3-3Composition (wt. part). Aromatic 80 80 90 85 80 80 80 polycarbonateresin (1) Granular talc (1) 20 — — — — — — Granular talc (2) — 20 10 15— — — Powdery talc — — — — 20 — — Compressed talc — — — — — 20 —Granular talc (3) — — — — — — 20 Organic alkali metal 0.1 0.1 0.1 0.050.1 0.1 0.1 salt Silicone-based resin — — — 0.5 — — — Fluorinated 0.50.5 0.5 0.5 0.5 0.5 0.5 polyolefin Phosphorus-based 0.3 0.3 — 0.3 0.30.3 0.3 compound (1) Phosphorus-based — — 0.1 — — — — compound (2)Evaluation results Extrusion ◯ ◯ ◯ ◯ X X X moldability Rigidity: Bending4650 4600 3400 3950 4450 4480 4550 modulus (MPa) Flame retardancy UL94:1.6 mmt V-0 V-0 V-0 V-0 V-1 V-1 V-1 1.2 mmt V-0 V-0 V-0 V-0 not-V not-Vnot-V Impact resistance: 29 37 59 48 11 13 12 Surface impact strength(J) Thermal stability ◯ ◯ ◯ ◯ X X X (ordinary molded product): Surfaceappearance

TABLE 9 Comparative Examples Examples 3-5 3-6 3-7 3-4 3-5 3-6Composition (wt. part) Aromatic polycarbonate 85 85 70 85 85 85 resin(1) Aromatic polycarbonate — — 20 — — — resin (2) Granular talc (1) 15 —— — — — Granular talc (2) — 15 10 — — — Powdery talc — — — 15 — —Compressed talc — — — — 15 — Granular talc (3) — — — — — 15 Organicphosphorus-based 10 10 8 10 10 10 flame retardant Fluorinated polyolefin0.5 0.5 0.5 0.5 0.5 0.5 Rubber polymer 6 6 5 6 6 6 Phosphorus-basedcompound 0.1 0.1 0.1 0.1 0.1 0.1 (1) Antioxidant 0.05 0.05 0.05 0.050.05 0.05 Release agent 0.2 0.2 0.2 0.2 0.2 0.2 Evaluation resultsExtrusion moldability ◯ ◯ ◯ ◯ ◯ ◯ Rigidity: Bending modulus 4050 40303400 3900 3930 3970 (MPa) Flame retardancy UL94: 1.2 V-0 V-0 V-0 V-1 V-1V-1 mmt Impact resistance: Surface 45 53 59 18 21 22 impact strength (J)Thermal stability ◯ ◯ ◯ X X X (ordinary molded product): Surfaceappearance

TABLE 10 Comparative Examples Examples 3-8 3-9 3-7 3-8 3-9 Composition(wt. part) Aromatic polycarbonate 20 30 20 20 20 resin (1) Aromaticpolycarbonate 40 34 40 40 40 resin (3) ABS resin (1) 10 12 10 10 10 ABSresin (2) 5 4 5 5 5 Granular talc (2) 25 20 — — — Powdery talc — — 25 —— Compressed talc — — — 25 — Granular talc (3) — — — — 25 Organicphosphorus- 14 14 14 14 14 based flame retardant Fluorinated polyolefin0.5 0.5 0.5 0.5 0.5 Phosphorus-based 0.1 0.1 0.1 0.1 0.1 compound (1)Antioxidant 0.05 0.05 0.05 0.05 0.05 Release agent 0.2 0.2 0.2 0.2 0.2Evaluation results Extrusion moldability ◯ ◯ X X X Rigidity: Bending6400 5500 6200 6240 6300 modulus (MPa) Flame retardancy V-0 V-0 V-1 V-1V-1 UL94: 1.2 mmt Impact resistance: 33 45 12 13 11 Surface impactstrength (J) Thermal stability (retention molded product): Surfaceappearance ◯ ◯ X X X Surface impact 19 35 2 2 1 strength (J)

From the results of Examples and Comparative Examples shown in Tables 8to 10, the followings were confirmed. The resin compositions obtained inExamples 3-1 to 3-4 according to the present invention were excellent inextrusion moldability, rigidity, flame retardancy, impact resistance andthermal stability. On the other hand, the resin compositions obtained inComparative Examples 3-1 to 3-3 in which the content of the component Bwas out of the specific range defined by the present invention weredeteriorated in extrusion moldability, flame retardancy, impactresistance and thermal stability.

The resin compositions obtained in Examples 3-5 to 3-7 were excellent inextrusion moldability, rigidity, flame retardancy, impact resistance andthermal stability. On the other hand, the resin compositions obtained inComparative Examples 3-4 to 3-6 in which the content of the component Bwas out of the specific range defined by the present invention weredeteriorated in flame retardancy, impact resistance and thermalstability.

The resin compositions obtained in Examples 3-8 and 3-9 were excellentin extrusion moldability, rigidity, flame retardancy, impact resistanceand thermal stability. On the other hand, the resin compositionsobtained in Comparative Examples 3-7 to 3-9 in which the content of thecomponent B was out of the specific range defined by the presentinvention were deteriorated in extrusion moldability, flame retardancy,impact resistance and thermal stability.

Although the present invention is described above with respect toembodiments which are considered to be most practical and preferable atthe present time, the present invention is not limited to theseembodiments described in the present specification, and various changesand modifications will be appropriately made within the scope of claimsand a whole description of the present specification unless departingfrom the subject matter and concept of the present invention, and itshould be construed that these changes and modifications are involved inthe technical scope of the present invention. Meanwhile, the presentpatent application is based on Japanese Patent Application (No.2006-60303) filed on Mar. 6, 2006, Japanese Patent Application (No.2006-60304) filed on Mar. 6, 2006 and Japanese Patent Application (No.2006-118980) filed on Apr. 24, 2006, the entire contents of which areincorporated herein by reference thereto.

1-29. (canceled)
 30. A process for producing a thermoplastic resincomposition comprising: 40 to 99 parts by weight of a resin component(component A) comprising 50 to 85% by weight of an aromaticpolycarbonate resin (component A1) and 50 to 15% by weight of athermoplastic polyester resin (component A2) with the proviso that atotal content of the components A1 and A2 is 100% by weight; 1 to 60parts by weight of a granular talc (component B) having a bulk densityof 0.4 to 1.5 g/mL which is obtained by granulating a talc having anaverage particle size of 0.1 to 10 μm; and 1 to 35 parts by weight of arubber polymer (component C), said process comprising using saidgranular talc (component B) which has the particle size in which aproportion of a 500 μm-mesh screen residue thereof is not less than 55%by weight, which granular talc (component B) is produced by granulatingsaid talc by using a binder and a lubricant and controlling the watercontent in the granular talc to not more than 1%, which binder comprisesa water-soluble polymer blended in the granular talc (component B) in anamount of 0.01 to 5% by weight, which lubricant is water blended in anamount of 10 to 150 parts by weight on the basis of 100 parts by weightof a total amount of the material talc and binder.
 31. The processaccording to claim 30, wherein the granular talc (component B) has aparticle size in which a proportion of a 500 μm-mesh screen residuethereof is not less than 75% by weight.
 32. The process according toclaim 30, wherein the component A2 comprises at least 10 parts by weightof a polyethylene terephthalate resin on the basis of 100 parts byweight of the component A2.
 33. The process according to claim 30,wherein a content of the rubber polymer (component C) in the compositionis 1 to 30 parts by weight on the basis of 100 parts by weight of atotal amount of the components A, B and C.
 34. The process according toclaim 30, wherein the rubber polymer (component C) is a core/shell-typegraft copolymer.
 35. The process according to claim 30, furthercomprising a phosphorus-based compound (component D) in an amount of0.005 to 1 part by weight on the basis of 100 parts by weight of a totalamount of the components A, B and C.
 36. A resin molded product producedby molding the thermoplastic resin composition as defined in claim 30.37. A process for producing a thermoplastic resin compositioncomprising: 40 to 99 parts by weight of an aromatic polycarbonate resin(component A); 1 to 60 parts by weight of a granular talc (component B)having a bulk density of 0.4 to 1.5 g/mL which is obtained bygranulating a talc having an average particle size of 0.1 to 10 μm; anda rubber polymer (component C) in an amount of 3 to 35 parts by weighton the basis of 100 parts by weight of a total amount of the componentsA and B, said process comprising using said granular talc (component B)which has the particle size in which a proportion of a 500 μm-meshscreen residue thereof is not less than 55% by weight, which granulartalc (component B) is produced by granulating said talc by using abinder and a lubricant and controlling the water content in the granulartalc to not more than 1%, which binder comprises a water-soluble polymerblended in the granular talc (component B) in an amount of 0.01 to 5% byweight, which lubricant is water blended in an amount of 10 to 150 partsby weight on the basis of 100 parts by weight of a total amount of thematerial talc and binder.
 38. The process according to claim 37, whereinthe granular talc (component B) has a particle size in which aproportion of a 500 μm-mesh screen residue thereof is not less than 75%by weight.
 39. The process according to claim 37, wherein a content ofthe rubber polymer (component C) in the resin composition is 5 to 25parts by weight on the basis of 100 parts by weight of a total amount ofthe components A and B.
 40. The process according to claim 37, whereinthe rubber polymer (component C) is a core/shell-type graft copolymer.41. A resin molded product produced by molding the thermoplastic resincomposition as defined in claim
 37. 42. A process for producing athermoplastic resin composition comprising: 40 to 99 parts by weight ofa resin component (component A) comprising 50 to 100% by weight of anaromatic polycarbonate resin (component A1) and 50 to 0% by weight of athermoplastic resin other than the aromatic polycarbonate resin(component A2) with the proviso that a total content of the componentsA1 and A2 is 100% by weight; 1 to 60 parts by weight of a granular talc(component B) having a bulk density of 0.4 to 1.5 g/mL which is obtainedby granulating a talc having an average particle size of 0.1 to 10 μm;and at least one flame retardant (component E) selected from the groupconsisting of an organic alkali metal salt and/or an organic alkaliearth metal salt (component E1), an organophosphorus-based flameretardant (component E2) and a silicone-based resin (component E3); anda fluorinated polyolefin (component F), said components E and F beingpresent in amounts of 0.01 to 40 parts by weight and 0.01 to 5 parts byweight, respectively, on the basis of 100 parts by weight of a totalamount of the components A and B, said process comprising using saidgranular talc (component B) which has the particle size in which aproportion of a 500 μm-mesh screen residue thereof is not less than 55%by weight, which granular talc (component B) is produced by granulatingsaid talc by using a binder and a lubricant and controlling the watercontent in the granular talc to not more than 1%, which binder comprisesa water-soluble polymer blended in the granular talc (component B) in anamount of 0.01 to 5% by weight, which lubricant is water blended in anamount of 10 to 150 parts by weight on the basis of 100 parts by weightof a total amount of the material talc and binder.
 43. The processaccording to claim 42, wherein the granular talc (component B) has aparticle size in which a proportion of a 500 μm-mesh screen residuethereof is not less than 75% by weight.
 44. The process according toclaim 42, wherein the component A2 is a styrene-based resin.
 45. Theprocess according to claim 42, further comprising a rubber polymer(component C) in an amount of to 1 to 30 parts by weight on the basis of100 parts by weight of a total amount of the components A and B.
 46. Theprocess according to claim 45, wherein the rubber polymer (component C)is a core/shell type graft copolymer.
 47. A process for producing aresin molded product comprising producing a thermoplastic resincomposition by the process as defined in claim 42 and molding thethermoplastic resin.